Pivot-fit connection apparatus, system and method for photovoltaic modules

ABSTRACT

A system and method are disclosed for quickly and easily assembling PV modules into a PV array in a sturdy and durable manner. In examples of the present technology, the system includes various couplings having a first engaging portion adapted to engage a first PV module and a second engaging portion adapted to engage a second PV module. At least one of the engaging portions allows variable positioning of the engaged PV module along the engaging portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.12/830,250, entitled “Pivot-Fit Connection Apparatus, System, and MethodFor Photovoltaic Modules”, filed Jul. 2, 2010, which claimed to U.S.Provisional Patent Application No. 61/270,122, entitled “Forming andMounting a Photovoltaic Array,” filed Jul. 2, 2009; U.S. ProvisionalPatent Application No. 61/255,004, entitled “Forming and Mounting aPhotovoltaic Array: Hardware and Software Improvements,” filed Oct. 26,2009; U.S. Provisional Patent Application No. 61/351,586, entitled,“Pivot-Fit Connection System, Apparatus and Method for PhotovoltaicArrays,” filed Jun. 4, 2010. Each of the above applications areincorporated by reference herein in their entirety.

BACKGROUND

Photovoltaic (PV) arrays are formed by mechanically linking together PVmodules into an array. Most PV module coupling systems require thetime-consuming use of multiple small fasteners. High part count and slowinstallation time is a major barrier to reducing PV system costs andadoption. Some attempts have been made to reduce fastener usage bydeveloping press-fit and hook-type connections. However, these systemssuffer from a number of drawbacks.

First, neither of these methods can adequately account for variations inthe dimensions of PV modules and couplings due to manufacturingtolerances. PV modules typically vary by approximately ±0.10″ along thelength and/or width dimension. When multiple modules are formed intocolumns in the north-south direction of the PV array, it is criticalthat any dimensional variations from one module in the column not carryforward to the next module in the column, as the dimensional variationswill add up over the length of the column and result in significantdimensional differences from one column to the next. Likewise, the sameproblem exists with east-west rows of PV modules. This problem,frequently referred to as tolerance take-up, is solved in rail-basedsystems by spacing the modules in a column more or less from each otheron top of mounting rails so that the next module in the column isproperly positioned and/or by only linking modules to the rails alongone axis, either east-west or north-south. However, in rail-freesystems, a PV module is structurally connected to the next module inboth the north-south direction and the east-west direction. Thus, if theseams between adjacent east-west modules do not line up because ofcompounded north-south dimensional variations, then it may be impossibleto complete the installation of an array. In other systems compoundedeast-west variations may cause problems along the north-south axis.Press-fit and hook-type connections do not adequately address or solvethe problem of tolerance variations.

Second, press-fit and hook-type connections do not provide a reliableelectrical ground bond between adjacent PV modules. Hook-typeconnections are inherently loose-fitting and thus incapable of providinga consistent, low-resistance ground bond that will withstand weatherconditions over time. Similarly, a press-fit connection does not providea reliable ground bond unless the materials are deformed enough in theconnection. In practice, too much force is required to achieve suchdeformation with standard PV module frame materials such as aluminum,thereby eliminating any time and cost savings that might have occurredsince a heavy-duty tool would be required to deliver the force neededfor the deformation.

Third, press-fit and hook-type systems cannot reliably provide a strong,durable connection between mating male and female parts. In order tofacilitate a quick and easy connection, the female receiving portion inthe connection is made wider than the male connecting portion. Thisresults in a loose or unstable connection, which is vulnerable toloosening over time as the PV modules experience mechanical stress dueto wind and snow loads.

It is also important to note that PV mounting systems require a designthat works with a wide tolerance band. The reason is that production oftight tolerance PV modules and couplings is very expensive. In order toaccelerate the adoption of solar power, it is necessary to reduce thecost of solar arrays, thus increased costs for tight tolerance parts isnot a viable option in the market.

SUMMARY

Disclosed herein is a system and method for quickly and easilyassembling PV modules into a PV array in a sturdy and durable manner. Insome embodiments, the PV modules may have a grooved frame where thegroove is angled into the frame with respect to the planar surface ofthe modules. Various components may engage within the angled groove toassemble the PV modules into the PV array using what may be referred toas a pivot-fit connection between the components and angled groove. Onetype of component is a leveling foot which in some embodiments includesa foot mounted to a support surface and a coupling affixed to the foot.The coupling of the leveling foot may have a male component such as atongue for coupling within the groove. In order to mount a PV module tothe leveling foot, the module is seated on the tongue and rotated downuntil the angle of the groove substantially aligns with the axis of thetongue. The groove may then seat at least partially over the tongue. Tocomplete the pivot-fit connection, the PV module is simply pivoted downto its final angular orientation in the PV array. This final rotationcauses bearing portions in the groove to bear against the tongue torestrain the PV module against upward or downward movement. The couplingmay still allow for adjustment of the PV module position in the plane ofthe PV array to account for tolerance variations.

Another type of coupling is an interlock having an interlock plate and apair of couplings, each having a key supported on a shaft. The interlockmay be affixed into the groove of a pair of adjacent modules with theangle of the key and shaft substantially matching the angle of thegroove. Thereafter, rotation of the key and shaft pivots the interlockinto the grooves of the adjacent PV modules, thereby affixing theadjacent modules together. This final rotation causes bearing portionsin the groove to bear against the interlock plate to resist upward ordownward movement of the coupled PV modules. The coupling may stillallow for adjustment of the PV module position in the plane of the PVarray to account for tolerance variations.

Further embodiments of the present technology may operate with PVmodules having frames without the angled grooves. For such embodiments,wraparound brackets are used which engage the upper and lower surfacesof the module frame, or the PV laminate itself in some embodiments wherethe frame is omitted. In such embodiments, the wraparound component mayhave frame-engaging or laminate-engaging couplings provided at an angleas in the angled groove of the above embodiments. The PV modules mayinitially engage with the wraparound components substantially at theangle of the couplings, and thereafter be pivoted down to their finalposition relative to the coupling. As in the grooved frame embodiments,this final rotation causes bearing portions in the wraparound couplingto bear against the PV module frame to restrain the PV module inposition in the array.

An embodiment of the present technology relates to an array ofphotovoltaic modules connected together by couplings. The first couplingof said couplings includes: a first engaging portion adapted to engage afirst photovoltaic module; and a second engaging portion adapted topivotally engage a second photovoltaic module along a length of a sideof said second photovoltaic module, said length being substantiallyparallel with a plane of a laminate of said second photovoltaic module;wherein said second engaging portion is adapted to allow variablepositioning of said second photovoltaic module relative to said firstcoupling in a direction substantially parallel with said plane andperpendicular to said length.

Another embodiment relates to a coupling for connecting a photovoltaicmodule to an adjacent photovoltaic module in a photovoltaic array. Theadjacent photovoltaic module comprising a frame, the coupling includes:a first engaging portion adapted to engage said photovoltaic module; anda second engaging portion adapted to engage said adjacent photovoltaicmodule at an insertion angle greater than 2 degrees relative to a planeof said photovoltaic module, wherein at least one of said secondengaging portion and said frame is adapted to flex open as at least oneof said coupling and said frame is rotated from said insertion angle toa position substantially parallel with said plane.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter. Furthermore, the claimed subject matter is not limited toimplementations that solve any or all disadvantages noted in any part ofthis disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a PV array mounted on a roof.

FIG. 2 is a perspective view of a PV module used in the PV array of FIG.1.

FIG. 3 is a cross-sectional view through line 3-3 of FIG. 2.

FIG. 4 is a cross-sectional view showing a groove in the frame of the PVmodule.

FIG. 4A illustrates the geometries defined by the sloped surfaces of thegroove formed in the frame of the PV module according to an embodimentof the present technology.

FIG. 5 is a cross-sectional view of the frame showing a grooveconfiguration according to an alternative embodiment of the presenttechnology.

FIG. 6 is a cross-sectional view of the frame showing a grooveconfiguration according to a further alternative embodiment of thepresent technology.

FIGS. 6A and 6B are front and cross-sectional views of the frame showinga bearing surface configuration according to a further alternativeembodiment of the present technology.

FIG. 7 illustrates the PV array of FIG. 1 during fabrication.

FIG. 8 is a first perspective view of a leveling foot according to anembodiment of the present technology.

FIG. 9 is a second perspective view of a leveling foot according to anembodiment of the present technology.

FIG. 10 is a side view of a leveling foot according to an embodiment ofthe present technology.

FIGS. 10A and 10B are perspective view of a leveling foot according toan alternative embodiment of the present technology.

FIG. 11 is a side view of a PV module and mounting feet being mounted tothe support surface according to an embodiment of the presenttechnology.

FIG. 12 is an enlarged side view showing the PV module frame groovesliding over the leveling foot tongue at an insertion angle according toan embodiment of the present technology.

FIG. 13 is an enlarged side view showing the final coupling of a PVmodule frame groove to a leveling foot tongue according to an embodimentof the present technology.

FIG. 13A is a further enlarged side view showing the bearing portionsbearing against a connecting component.

FIG. 14 is a perspective view as in FIG. 1 showing the array duringfabrication on the support surface.

FIG. 15 is an exploded perspective view of a first side of an interlockaccording to an embodiment of the present technology.

FIG. 16 is a perspective view of an interlock coupling according to anembodiment of the present technology.

FIG. 17 is a perspective view of the first side of an interlockassembled together according to an embodiment of the present technology.

FIG. 18 is a perspective view of a second side of an interlock accordingto an embodiment of the present technology.

FIG. 19 is a cross-sectional side view of an interlock showing a key ina first position.

FIG. 20 is a cross-sectional side view of an interlock showing the keyrotated 90° from that shown in FIG. 19.

FIG. 21 is a cross-sectional side view of a PV module receiving aninterlock according to an embodiment of the present technology.

FIG. 22 is an enlarged cross-sectional side view showing the coupling ofthe interlock shown in FIG. 21 partially rotated.

FIG. 23 is an enlarged cross-sectional side view showing an interlockfully rotated and locked in position within the module frame grooveaccording to an embodiment of the present technology.

FIG. 24 is a perspective view of a pair of panels joined together by aninterlock and a leveling foot supporting the panels according to anembodiment of the present technology.

FIG. 24A is a plan view showing four PV modules affixed by an interlockwhere at least some of the PV modules are misaligned.

FIG. 25 is a perspective view of a combined leveling foot and interlockcoupling according to an embodiment of the present technology.

FIG. 26 is a perspective view of a grounding coupling used for groundingthe PV array according to an embodiment of the present technology.

FIG. 27 is a perspective view of an accessory coupling used for affixingadditional components to a PV array according to an embodiment of thepresent technology.

FIG. 28 is a perspective view of the coupling of FIG. 27 coupling acomponent to a PV array according to an embodiment of the presenttechnology.

FIG. 29 is a perspective view of a leveling foot for receiving a frameof a PV module that does not include a groove according to an embodimentof the present technology.

FIG. 30 is a cross-sectional side view of the leveling foot of FIG. 29.

FIG. 30A is a perspective view of a leveling foot for receiving a frameof a PV module that does not include a groove according to a furtherembodiment of the present technology.

FIG. 31 is an alternative embodiment of an interlock for mounting PVmodules which do not have a groove in the frame according to anembodiment of the present technology.

FIG. 32 is a cross-sectional side view of the interlock of FIG. 31.

FIGS. 32A and 32B are a further alternative embodiment of an interlockfor mounting PV modules which do not have a groove in the frameaccording to an embodiment of the present technology.

FIG. 32C is a leveling foot formed with the alternative embodiment shownin FIGS. 32A and 32B according to an embodiment of the presenttechnology.

FIG. 32D is an interlock for mounting PV modules which do not have agroove in the frame according to an alternative embodiment of thepresent technology.

FIG. 33 is a perspective view of at least a portion of a PV array formedwith the couplings of FIGS. 29 through 32.

FIG. 34 is a cross-sectional side view of a further embodiment of aninterlock coupling for coupling together PV laminates that do notinclude a frame.

FIG. 35 is a cross-sectional end view of a rail for supporting theinterlock coupling of FIG. 34.

FIG. 36 is a plan view of at least a portion of an array formed with theinterlock coupling of FIG. 34.

FIG. 37 is a perspective view of a further embodiment of a coupling forworking with grooved-frame PV modules on a flat roof according to anembodiment of the present technology.

FIG. 38 is a cross-sectional side view of the coupling of FIG. 37.

FIG. 39 is a cross-sectional side view of a coupling for operating withPV module frames which do not have a groove and which are adapted to bemounted on a flat roof according to an embodiment of the presenttechnology.

FIG. 40 is a plan view of at least a portion of an array formed with thecouplings of FIG. 38 or 39.

FIG. 41 is a perspective view of a further embodiment of couplings forassembling a PV module into an array while the PV module is inclinedabout both the X-axis and Y-axis.

FIG. 42 is an edge view of a double-key coupling having a pair ofopposed keys according to an embodiment of the present technology.

FIG. 43 is a perspective of the double-key coupling as shown in FIG. 42as may be used in a PV array.

FIGS. 44-45 show perspective and front views of a front tilt footaccording to embodiments of the present technology.

FIG. 46 shows a perspective view of a rear tilt foot according toembodiments of the present technology.

FIG. 47 is a side view of the front and rear tilt feet supporting a PVmodule according to embodiments of the present technology.

FIG. 48 is a perspective view of the front and rear tilt feet supportingPV modules according to embodiments of the present technology.

FIGS. 49 and 50 are side and perspective views of mid-support couplingsupporting PV modules according to embodiments of the presenttechnology.

FIGS. 51 and 52 are perspective and side views of a double-tongueleveling foot according to embodiments of the present technology.

FIG. 52A is a perspective view of a double-tongue leveling footaccording to an alternative embodiment of the present technology.

FIGS. 53 and 54 are perspective views of a stamped interlock with andwithout interlock couplings according to embodiments of the presenttechnology.

FIGS. 55 and 56 are perspective and side views of a hybrid press-fitcoupling according to embodiments of the present technology.

FIGS. 57 and 58 are front and rear perspective views of a modularcoupling according to embodiments of the present technology.

FIG. 59 is a perspective view of a pair of modular accessory couplingsaffixed to a PV module according to embodiments of the presenttechnology.

FIGS. 60 and 61 are perspective and side views of a hybrid foot bracketsupporting PV modules according to embodiments of the presenttechnology.

FIG. 62 is a side view of a key slot-engaging coupling according toembodiments of the present technology.

DETAILED DESCRIPTION

Embodiments of the present technology will now be described withreference to FIGS. 1-62, which in general relate to a system, apparatusand method for quickly and easily assembling a PV array in a sturdy anddurable manner. It is understood that the present technology may beembodied in many different forms and should not be construed as beinglimited to the embodiments set forth herein. The terms top, bottom,upper, lower, left, right, north, south, east, west, and derivations ofthese terms as they may appear in this description are used forconvenience and illustrative purposes only, and are not meant to limitthe description inasmuch as the referenced item can be exchanged inposition.

Referring now to FIG. 1, there is shown a perspective view of a PV array100 including a plurality of PV modules 102 laid out in an x-y referenceplane on a support structure 103. Mounting structure 103 is herein shownas including a planar surface, however it may be a structure withthickness, width, depth, and other dimension(s); in reference to anymounting structure, such as mounting structure 103, the heightadjustment of a coupling described hereinafter is considered relative toany essential surface or essential plane, such as a top surface. They-direction corresponds to the north-south dimension of the array, andthe x-direction corresponds to the east-west direction. In theembodiment of FIG. 1, the reference plane is defined as beingcoextensive with a surface of the PV modules, when the PV modules arepositioned in their final installed positions. However, in furtherembodiments, some of which are illustrated below, the reference planemay be above an upper surface of the PV modules 102, or below the lowersurfaces of the PV modules 102. The PV array 100 may be assembledtogether and attached to the support structure 103 by means of levelingfeet, wraparound leveling feet, double-tongue feet, key coupling feet,brackets, feet, tilt feet, or T-feet, such as leveling feet 104, andinterlocks, wraparound interlocks, series coupling rails,series/parallel couplings, male coupling members, splices, parallelcouplings, double-key couplings, or key couplings, such as interlocks106, the structure and operation of which are explained below. Othercomponents may be coupled to array 100 such as for example a groundingcoupling and accessory coupling, also explained below. The PV array 100of FIG. 1 is shown by way of example only. It is understood that array100 may have more or less modules 102 in the x and/or y direction. Inthe embodiment shown, the support structure 103 may be a roof, such as aslanted roof of a residential dwelling or the like. However, it isunderstood that the PV array 100 may be supported on a wide variety ofother support surfaces, such as for example a flat roof, aground-mounted structure or, in some embodiments, a vertical supportstructure. The defined x-y reference plane of the PV array issubstantially parallel to support structure 103, and may be oriented inany of a wide variety of angles from horizontal to vertical.

FIG. 2 is a perspective view of a PV module 102 used in the array 100. APV module, such as PV module 102, without a groove according to thepresent technology, is generally disclosed in U.S. Pat. No. 7,592,537,entitled “Method and Apparatus for Mounting Photovoltaic Modules,” whichpatent is incorporated by reference herein in its entirety. In someembodiments, module 102 may include a PV laminate 110 surrounded andsupported on two or four sides by a frame 112. PV laminate 110 mayinclude any of various photovoltaic materials for converting solarradiation to electric current. Frame 112 may be formed of any of variousrigid or semi-rigid materials, including for example extruded aluminumwith an anodized coating. Other materials, plastics, and coatings arecontemplated.

Frame 112 may include a hollow portion for connecting the cornerstogether with corner keys, as is well-known in the art, or it mayinclude screw receptacles for attaching the corners together withscrews, as is also well-known. Frame 112 may include a connectionportion such as groove 114 in accordance with the present technologyprovided on one, two, three or all four exterior facing portions of theframe 112, usually with an external surface 113. FIG. 3 illustrates across-sectional side view through line 3-3 of FIG. 2 showing furtherdetail of groove 114. In some embodiments, groove 114 may have the samecross-sectional configuration around the entire periphery of frame 112,though different sides may have different configurations in furtherembodiments. FIG. 4 is a partial cross-sectional view showing a singleside of the frame 112. As seen in FIG. 4, a groove 114 may in general bedivided into three vertical regions (from the perspective of FIG. 4). Aproximal region 116 adjacent to an external surface 113 of frame 112, adistal region 120 defining a back wall of groove 114 and locatedfarthest from the external surface 113 of frame 112, and a medial region118 between the proximal and distal regions.

Proximal region 116 may be defined by a pair of sloped surfaces—uppersloped surface 122 and lower sloped surface 126. Sloped surfaces 122 and126 may in general be parallel to each other and sloped at an angle of15° with respect to a planar surface of module 102 (such as, a plane inwhich a surface of PV laminate 110 resides). It is understood thatsloped surfaces 122 and 126 need not be parallel to each other, and mayform other oblique angles with respect to the planar surface of themodule 102 that are less than or greater than 15° in furtherembodiments. The angle of sloped surfaces 122 and 126 with respect tothe planar surface of module 102 defines an angle, referred to herein asthe insertion angle, which is explained in greater detail below. Furtherexamples of the insertion angle include but are not limited to 2° orgreater, 5° or greater, 10° or greater and 20° or greater.

Upper surface 122 includes a bearing portion 124, which represents thebottommost portion of upper surface 122 from the perspective of FIG. 4.Bearing portion 124 may be a line along the groove 114 where the slopedsurface 122 and the adjacent interior groove wall come together. Thebearing portion 124 may have a sharp profile, or the bearing portion mayinstead have a rounded or flattened profile in further embodiments.Similarly, lower sloped surface 126 may include a bearing portion 128,which represents the uppermost portion of lower surface 126 from theperspective of FIG. 3. Bearing portion 128 may be a line along thegroove 114 where sloped surface 126 and the adjacent interior wall cometogether. The bearing portion 128 may have a sharp profile, or thebearing portion may instead have a rounded or flattened profile infurther embodiments. Bearing portions 124 and 128 may be offset fromeach other horizontally; that is, bearing portion 128 may be located atthe external surface 113 of frame 112 and bearing portion 124 may belocated distally of the external surface 113 in the horizontaldirection.

Particular geometries defined by sloped surfaces 122 and 126 areexplained in greater detail now with respect to FIG. 4A. As noted above,sloped surfaces 122 and 126 may be parallel to each other in someembodiments of the present technology. In such an embodiment, adistance, m, represents the perpendicular distance between the twosloped surfaces 122 and 126. FIG. 4A also shows planes p and q (into thepage), which are planes through bearing portions 124 and 128,respectively, and which planes are substantially parallel to the planarsurface of module 102. A distance, n, is the perpendicular distancebetween planes p and q. In some embodiments, the distance m may begreater than the distance n. The significance of this is explained ingreater detail below. In some embodiments, the distance m may forexample be 0.51″ and the distance n may for example be 0.50″. Thesedimensions are by way of example only and may vary together ordisproportionately in further embodiments.

Medial region 118 includes an upper recess 130 a in an upper portion ofgroove 114 and a lower recess 130 b in a lower portion of groove 114(from the perspective of FIG. 4). Recesses 130 a and 130 b togetherdefine a key slot 130 in the medial portion of groove 114 for receivinga key of various couplings as described hereinafter. The length fromupper recess 130 a to lower recess 130 b may be longer than the distancebetween the sloped surfaces 122, 126. Distal region 120 is definedbetween the distal most portion of key slot 130 and a back wall 132 ofgroove 114.

In the embodiment described above, bearing portions 124, 128 areprovided in sloped surfaces 122, 126, respectively. It is understoodthat bearing portions 124 and/or 128 may be provided in other shapedsurfaces of frame 112 in other embodiments. As one such example, FIG. 5shows a bearing portion 128 in a sloped surface as described above.However, bearing portion 124 may be a protrusion from an otherwiseessentially flat surface parallel to the planar surface of the module102. Bearing portion 128 may be formed as a protrusion on an otherwiseflat surface in addition to, or instead of, the bearing portion 124 infurther embodiments. Given this disclosure and the disclosure thatfollows, those of skill in the art will appreciate other possibleconfigurations of the surfaces including bearing portions 124, 128, withthe provision that bearing portions 124 and 128 are spaced from eachother vertically and offset from each other horizontally. The distance mof FIG. 4A is found in FIG. 5 in a manner similar to FIG. 4A. In FIG. 5as shown, a first plane r may be defined which is tangential to bearingprojection 124 and the proximal (outer) edge of the upper sloped surface122. A second plane s may be defined which is tangential to bearingprojection 128 and the distal (inner) edge of the lower sloped surface126. The distance m may be defined by the perpendicular distance betweenthe two defined planes.

In addition to variations in proximal region 116 as described above,regions 118 and/or 120 may have other configurations in furtherembodiments. For example, FIG. 6 shows a cross-sectional side view as inFIG. 4, but key slot 130 is omitted. In some embodiments, frame 112 mayhave four sides, with a first side having a configuration as shown inFIG. 4, and an opposed side having a configuration as shown in FIG. 6,or other configurations as may be apparent to those with skill in theart. In other embodiments, frame 112 may have two sides with grooves 114and two sides with no groove.

As explained below, the present technology includes couplings with malecomponents that mate within female components, such as the groove 114,at the insertion angle. In another embodiment it is contemplated thatone or more of the respective positions of the male components and/orfemale components may be reversed, so that the frame includes or formsprotruding male components, and the couplings include female componentsreceiving the male components of the frame at the insertion angle.

FIGS. 6A and 6B show a further embodiment of the frame 112, where FIG.6A is a front view of a frame 112, and FIG. 6B is a cross-sectional viewthrough line A-A of FIG. 6A. In this embodiment, frame 112 does not havean angled groove 114 with bearing surfaces 124, 128 as described above,and the structure of frame 112 defining the proximal section 116, medialsection 118 and distal section 120 may be omitted. In this embodiment,the bearing surface 128 may be defined by a hole 127 formed through afront surface 113 of the frame 112. The bearing surface 124 may bedefined by a hole 129 formed through a rear surface 115 of the frame 112opposite the front surface 113. The holes 127, 129 may be circular witha variety of diameters, and formed by drilling through the front andrear surfaces 113, 115. However, the holes may be square, rectangular,oval or other shapes and formed by methods other than drilling infurther embodiments. The bearing surface 128 may be on a bottom portionof the hole 127 and the bearing surface 124 may be on a top portion ofhole 129.

As seen in FIG. 6A, the holes 127, 129 may be aligned with each otherhorizontally from the perspective of FIG. 6A, but the hole 127 definingbearing surface 128 may be vertically higher than the hole 129 definingbearing surface 124. As explained hereinafter, various couplings areprovided having a male portion, such as for example a tongue 148 shownin FIGS. 8-10. These male portions may be inserted between bearingportions 128 and 124 shown in FIG. 4 at an insertion angle parallel tothe upper and lower surfaces 122 and 126 of frame 112. Thereafter, themale portion or frame 112 may be rotated so that the mail portionengages the bearing portions 128 and 124 to restrain relative movementbetween the male portion and bearing surfaces in a vertical direction.This feature of the present technology is explained in greater detailbelow.

Referring again to FIGS. 6A and 6B, the male couplings describedhereinafter may have a diameter and length to fit within both holes 127and 129. Where frame 112 is formed with holes 127 and 129 according tothis embodiment, a male coupling may be inserted through hole 127 andthen through hole 129. The coupling may be inserted at an insertionangle defined by an axis passing holes 127 and 129. As the holes arevertically offset from each other, this insertion angle may be greaterthan 0°, and may for example be 15°. Thereafter, the male portion orframe 112 may be rotated so that the mail portion engages the bearingsurfaces 128 and 124 to restrain relative movement between the maleportion and the bearing surfaces 128, 124 in a vertical direction.Again, this engagement is explained in greater detail hereinafter.

FIG. 7 is a perspective view, similar to FIG. 1, of an array-to-beduring fabrication of the PV array 100. The present technology relatesto a system of connecting components for a PV array which lies in areference plane. In general, the system connects together first andsecond connecting components. As explained below, the first and/orsecond connecting components may be any of PV laminates, PV modules, PVmodule frames, coupling members, and brackets. One of the connectingmembers includes a first, or upper, bearing portion and a second, orlower, bearing portion. These bearing portions may be the bearingportions 124 and 128 described above within groove 114. As explainedbelow, the bearing portions may be formed on other connecting componentsin further embodiments.

As is also explained below, the bearing portions may be offset from eachother in a direction substantially parallel to the reference plane. Forexample, in FIG. 4, a reference plane may be defined by the laminate 110of module 102. Bearing portion 124 is more distal than bearing portion128 from the perspective of FIG. 4 in a direction substantially parallelto the laminate 110 and the reference plane defined by laminate 110.

The first component may engage with the bearing portions in a way thatallows the first component to insert between the bearing portions.Thereafter, the first component may be pivoted to a position between thebearing portions where the bearing portions resist relative movement ofthe connecting components in a direction substantially perpendicular tothe reference plane, while permitting relative movement of saidconnecting components in a direction substantially parallel with thereference plane. These features are explained below.

FIG. 7 shows a first row of leveling feet 104 affixed to supportstructure 103. As indicated above, support structure 103 may be a roof,such as of a residential dwelling. Such roofs typically include raftersor joists (105 in FIG. 14) beneath the roof surface. In someembodiments, the positions of the leveling feet 104 along the x axis maycorrespond to the positions of the rafters or joists below such a roof,so that the leveling feet 104 bolt directly to the rafters or joists toensure the array 100 is properly supported. One skilled in the art willrecognize that the leveling foot may be oriented 90° from the positionshown if the rafters run east-west. As explained below, the couplingsaccording to the present technology may be used for PV arrays on othertypes of surfaces, in which case bolting leveling feet 104 to joists orrafters may not be a consideration. In such embodiments, the levelingfeet 104 may be positioned as desired, and may be combined withinterlocks (not shown), which may be similar to interlock 106 shown inFIG. 1, into an integrated coupling, such as at seams between modules(not labeled), which may be similar to modules 102 shown in FIG. 1, asexplained below.

Details relating to the configuration of an example leveling foot 104will now be described with reference to FIGS. 8 through 10. Thisdisclosure shows a mechanism for leveling photovoltaic arrays.Contrasting the instant mechanism is the use of a slot. Such slot mayreside in a vertical portion of a bracket which may further comprise abolt for variably tightening at different positions in the slot, such adevice is not considered a mechanism since it is simply a fastener and aslot. The apparatus shown herein may include a mechanism for leveling.In general, leveling foot 104 includes a base 134 that may be mounted toa support structure (not shown), which may be similar to supportstructure 103 shown in FIG. 1, via a bolt or other fastener (not shown)fitting through a mounting hole 136 adapted to expose a portion of thesupport surface. In some embodiments base 134 is fastened to a separatestructural member, rail, attachment device, or flashed attachmentdevice, such as a flashed post, instead of being attached directly tosupport structure 103. A further threaded hole 137 is provided in base134 for receiving a first end of double threaded stud 140.

Leveling foot 104 further includes a foot coupling 138 for coupling theleveling foot to a PV module, such as module 102. Coupling 138 isthreaded onto a second end of double threaded stud 140 through a hole136 in foot coupling 138. The threads of the coupling hole 136 may bereversed with respect to the threads in hole 137 in base 134. The doublethreaded stud 140 includes a tool-receiving recess 144 for receiving atool which may be used for rotating the double threaded stud 140. Uponrotation of stud 140 in a first direction, the foot coupling 138 movesaway from the base 134 to raise an attached PV module (not shown) awayfrom a support structure, such as support structure 103 shown in FIG. 7.Rotation of stud 140 in the opposite direction moves the foot coupling138 and attached PV module (not shown) closer to the support structure.It may happen that such support structure may not be flat but rather mayinclude local or global large and/or small peaks and valleys, whichpeaks and valleys are emphasized by the high reflective properties ofthe laminates. Mounting the foot coupling 138 for quick and easytranslation allows for correction of these peaks and valleys and ensuresa more effective planarity of the finished array, such as array 100 asshown in FIG. 1, in the x-y reference plane.

A height adjustment mechanism, such as stud 140, allows adjustment ofthe height of leveling foot 104 even after leveling foot 104 has beenconnected to PV module 102. Thus, height adjustment of leveling foot 104may be independent from the operation of engaging leveling foot 104 witha PV module 102 and/or support structure 103. Such an arrangement, asshown in FIG. 8, greatly simplifies the process of leveling a PV array,such as array 100, since an installer can still adjust the height ofleveling foot 104 even after it has been installed. One skilled in theart will recognize that height adjustment after leveling foot 104 hasbeen connected to module 102 and attached to support structure 103 meansthat an installer can easily see the planar relationship betweenadjacent PV modules (since the PV laminate very clearly defines a planedue to its glass surface) when making the final height adjustment,thereby substantially speeding up the process of bringing each of themodules 102 in array 100 into approximately the same plane. Adjustingthe height of various leveling feet 104 in array 100 after at least twoPV modules 102 are in place is much easier because PV modules 102 makeit easier to see the planar relationship between adjacent modules.Additionally, recess 144 may be positioned to allow rotation of stud 140from the top even after substantially all of the PV modules 102 in anarray 100 have been installed. This arrangement provides additionalbenefits during the process of leveling PV array 100 since it is easiestto see the overall plane of PV array 100 once the bulk of modules 102have been installed; thereby enabling, for example, an installer to goback out to a leveling foot located in the middle of the array andquickly adjust its height to fine tune the planarity of array 100.

It is contemplated that some or all components of leveling foot 104 maybe manufactured from corrosion-resistant materials or may comprisecorrosion-resistant coatings to prevent galvanic and/or moisture-inducedcorrosion. Since foot coupling 138 may provide a ground bondingconnection between adjacent PV modules, such corrosion resistance mayhelp to prevent a loss of ground continuity over time.

Those of skill in the art will appreciate a wide variety of other heightadjustment mechanisms which may be used in addition to, or instead of,the components described above. Moreover, base 134 may be modified orreplaced depending on the support structure on which the array ismounted. For example, base 134 may be replaced with a foot base adaptedfor attaching to seams or corrugations of metal roofs or a flash mountfoot base that incorporates a roof flashing into base 134. In a furtherembodiment, base 134 may be adapted for tile roofs, both of flat andundulating design. In still other embodiments base 134 may be adapted toattach to structural members such as strut, round or square tube steel,I-beam, etc. Those with skill in the art will appreciate that base 134may be adapted to seat properly on a variety of other support structuresor surfaces as well.

Foot coupling 138 of leveling foot 104 further includes a center portionor flange 146, a tongue 148 extending from one side of flange 146, and akey 150 provided on a shaft 152 extending from the opposite side offlange 146. A PV module may be mounted to a support structure by twoleveling feet on opposed sides of the module along the y-axis direction,as generally shown in FIG. 1, with the tongue 148 of the first levelingfoot fitting within a groove, such as groove 114 shown in FIGS. 3, 5 and6, on the first side, and the key 150 of the second leveling footfitting within a groove, such as groove 114, on the opposite side. Thisaspect of the present technology will be explained below with referenceto the perspective view of FIG. 7 and the side views of FIGS. 11 through13. The first row can be mounted either with all keys in or one side keyin and other side tongues in.

FIGS. 10A and 10B show an alternative embodiment of the leveling foot104. This embodiment may include a base 134 and a foot coupling 138 asdescribed above. However, in this embodiment, the foot coupling 138 maybe affixed to the base 134 via a foot stud 143. Foot stud 143 may bemounted to the base 134 for example via retention pins 141. In thisembodiment, a top portion of the stud 143 may be threaded, and fitwithin the threaded hold 142 in flange 146 of foot coupling 138. In thisembodiment, height of the foot coupling 138 may be adjusted relative tothe base 134 by rotating the coupling 138 on the stud 143 prior tocoupling the leveling foot 104 to modules 102.

In some embodiments, a first leveling foot (104 a in FIGS. 7, 11, 12 and13) may be mounted to a support surface. On a slanted roof, this may bethe leveling foot on the downhill side of the module 102 to be mounted.The leveling foot 104 a may be fastened to the support surface 103 sothat the tongue 148 of leveling foot 104 a is facing toward the sidewhere module 102 is to be affixed.

Module 102 may then be brought into contact with, and supported on,mounted leveling foot 104 a so that portions of the upper sloped surface122 of groove 114 rest on the tongue 148 of the mounted leveling foot104 a. Thereafter, the module 102 can be rotated downward in thedirection of the arrow shown in FIGS. 7 and 11. As discussed above, theupper and lower sloped surfaces 122, 126 may be provided at someinsertion angle, for example 15°, with respect to the planar surface ofmodule 102. FIG. 12 shows the module 102 having been rotated to thepoint where the angle of the module 102 with respect to the x-yreference plane is essentially equal and opposite to the insertion angleof the sloped surfaces 122, 126. At this point, the sloped surfaces 122,126 will be essentially parallel to the upper and lower surfaces of thetongue 148, and the groove 114 may then slide over the tongue 148 toseat the tongue 148 within groove 114 and to seat the module 102 onleveling foot 104 a. It is understood that the groove 114 may slide overthe tongue 148 when there is a few degrees difference between the two invarious embodiments. One skilled in the art will recognize that thenormal variation in the final dimensions of mating parts may result insome cases where the groove 114 may be slightly narrower than tongue 148even when positioned as shown in FIG. 12, yet groove 114 may still slideover tongue 148. Chamfer 147 on tongue 148 may help to start theinsertion process and grounding teeth 149 may then cut their way as itis slid into position.

FIG. 13 shows the module 102 upon further rotation to the finishedposition of the module 102 where the planar surface of the module 102 isgenerally parallel to the x-y reference plane. In this and otherembodiments described herein, the reference plane may be at or above theupper surface of the PV laminate 110 (as indicated by dashed line 155 ain FIG. 13), in between the upper and lower surfaces of the PV laminate110, at the lower surface of PV laminate 110 (for example as indicatedby dashed line 155 b in FIG. 13) or below the PV laminate 110 (asindicated by the dashed line 155 c in FIG. 13).

When the groove 114 slides over the tongue 148 in FIG. 12, the space inbetween the upper and lower sloped surfaces 122, 126 engaged by thetongue is the distance m described above in FIG. 4A. However, once themodule is rotated to the position shown in FIG. 13, the spacing betweenthe surfaces 122, 126 engaged by the tongue is the smaller distance n.In some embodiments, taking into account dimensional variations in thesurfaces 122, 126 and tongue 148, the height of the tongue may beslightly smaller than or equal to the distance m, and slightly largerthan or equal to the distance n. For example, the height of the tonguealong a dimension between the surfaces 122 and 126 may be 0.010″ smallerthan the distance m, and 0.010″ greater than the distance n. Thus, inembodiments, the tongue 148 and surfaces 122. 126 of groove 114 may havea cumulative tolerance range for mating parts of −0.010″ to +0.010″. Oneskilled in the art will recognize that the difference between m and nprovides a range for vertical (z-axis) tolerance takeup. In the previousexample, even a tongue that is 0.010″ undersized at the insertion anglemay result in a tight fit that flexes the frame open (in the directionof arrows 151) and thereby deforms the materials by 0.010″ in the final0° position. The size of the tongue 148 relative to the distances m, nmay vary from these dimensions in various embodiments. For example, theheight of tongue 148 may be greater than both m and n, so long as n issmaller than m.

The coupling, or connection, of the tongue 148 with the groove 114discussed above helps to point some of the benefits of the pivot-fitconnection. Such an arrangement allows for easy insertion of parts, yetsolid connections in the final position without having to rely oncumbersome press-fits (which are difficult given the materials,tolerances, and dimensions of typical PV modules) or mechanicalfasteners. Also, the fact that the insertion angle is different than thefinal angle may mean that the surface area of material in contact islower (than if the groove 114 had straight lips), thereby enabling a lowfriction, easy adjustment of alignment even in the final 0° position.Furthermore, the pivot-fit connection system may also help to increasethe amount of horizontal tolerance takeup.

As a result, after easily sliding over tongue 148 at the insertionangle, the module 102 may be rotated to the position shown in FIG. 13 toprovide a pivot-fit connection of the groove 114 to the tongue 148. Thisdisclosure may also refer to such a connection by saying that the tongue148 pivotally engages the groove 114 or the groove 114 pivotallyreceives the tongue 148. In particular, the bearing portion 124 in theupper sloped surface 122 bears against, and exerts a force downward on,the tongue 148 (such as in a z-direction perpendicular to the x-yreference plane). In the position of FIG. 13, the bearing portion 128 inthe lower sloped surface 126 similarly bears against, and exerts a forceupward on, the tongue 148 in the z-direction.

The PV module 102 provides a lever arm, and the moment force allows thePV module to pivot about bearing portion 124 from the position of FIG.12 to the position of FIG. 13 usually under the weight of module 102.This results in tongue 148 bearing against bearing portions 124, 128 ofsurfaces 122, 126, which elastically deforms the frame 112 around tongue148 via a flexing open of the frame. One skilled in the art willrecognize that the generally C-shaped connection portion 114 of frame112 may naturally flex open when loaded at the bearing portions 124,128. The bearing of the tongue against the surfaces 122, 126 takes upany variability in the z-axis dimensions of the tongue 148 and thegroove 114. This provides a tight coupling and prevents any relativemovement between the leveling foot 104 a and the portion of the coupledframe 112 along the z-axis. Those skilled in the art will recognize thateven if the height of the tongue 148 is greater than m, therebyrequiring the tongue 148 to open the groove 114 slightly duringinsertion at the insertion angle, a rotation to the final angle of FIG.13 increases the forces between the bearing portions 124, 128 and thetongue 148, thereby creating a final tight fit that is much tighter thanit may have been when rotated as shown in FIG. 12.

While constrained in the z-direction, the coupled frame portion 112 andmodule 102 are able to move in a direction of arrow 154 in FIG. 13 alongthe surface of the tongue 148. This allows the y-position of the module102 to be quickly and easily adjusted after the pivot-fit connection isestablished between the module and leveling foot 104 a, for example, inorder to account for any tolerance variations in the y-dimension of themodule 102. As explained in the Background section, this variablepositioning feature prevents or ameliorates dimensional variations fromadding up along the length of a column of modules in the y-direction. Asshown in FIG. 8, the tongue may include a catch 156 to preventdisengagement of the groove 114 from the tongue 148 while adjusting inthe y-direction. One skilled in the art will also recognize that thevariable positioning feature 154 of the pivot-fit connection may causethe pivot point, such as bearing portion 124 in the above example, toslide somewhat as the parts are being pivoted into position. In someembodiments bearing portions 128, 128 comprise non-concave shapes suchas convex, faceted, ribbed, etc., thereby ensuring an easy horizontaladjustability.

FIG. 13A shows a further enlarged view of the forces exerted by bearingportion 124 down on the tongue 148, and bearing portion 128 up on tongue148. In some embodiments, bearing portions may be formed so that thereis an interface area 125 between the bearing portion 124 and tongue 148where the two components lie in contact with each other. The sameinterface area 125 may exist between bearing portion 128 and tongue 148.The size of the interface area may be determined by the shape of thebearing portions 124, 128 and the degree of deformation of bearingportions 124, 128 and/or tongue 148.

Forces, F, are exerted by the bearing portion 124 down onto tongue 148.These forces are vector quantities with direction and magnitude, and maysum together into a resultant force vector FV1. Similarly, forces, F,are exerted by the bearing portion 128 up onto tongue 148. These forcesare vector quantities with direction and magnitude, and may sum togetherinto a resultant force vector FV2. In embodiments, the couplingdescribed above between the tongue 148 and the bearing surfaces 124, 128of groove 114 may result in equal and opposite force vectors FV1 andFV2. The contact areas 125 and resultant equal and opposite forcevectors FV1 and FV2 may result from any of the couplings described belowof a connecting component connecting with bearing portions. In furtherembodiments, the resultant force vectors FV1 and FV2 at bearing surfacesof a coupling need not be equal or opposite.

With the above described pivot-fit connection, the present technologyprovides an extremely fast and simple way to attach a PV module to acoupling such as a leveling foot. Through the simple act of sliding agroove in the module frame over a coupling at an insertion angle, andthen letting the module down to its final angular orientation, themodule is engaged in place and secured with respect to z-axis movement,while still being adjustable to account for dimensional differences inthe size of a module. The tolerance take-up mechanisms as describedabove also take-up dimensional variations in the size of matingcomponents as well as slight variations in the length of a row or columnof modules due to other factors such as misalignment of mating parts andthe unevenness of the mounting structure.

The tongue 148 may include an electrical ground tooth 149 (one of whichis shown in FIGS. 8 and 9), in the form of an inverse v-shapedprotrusion extending from the upper surface of the tongue 148 along they-dimension when oriented as shown in FIG. 7. It may alternatively be av-shaped protrusion extending from the lower surface of the tongue 148along the y-dimension. Other shapes of teeth or other configurations forelectrical grounding are explicitly contemplated herein but hereaftergenerally described as a cutting tooth or teeth. When the module 102 ispivoted to its final position so that there is a tight fit of the tongue148 between the upper and lower surfaces 122, 126, the ground tooth maybite through the anodized layer and into electrical contact with themetal underneath to establish an electrical ground contact with theconnection portion 114 of module 102. The key 150 (see FIGS. 8, 9, 10and 11) on the opposite side of leveling foot 104 may also include oneor more cutting teeth as explained below for establishing a groundconnection to the connection portion 114 of the module it couples with.Thus, the leveling foot may provide a grounding bond between modulesalong the y-dimension or x-dimension when oriented with the tonguefacing east-west. One skilled in the art will recognize that theconnection portion of PV module frame 112 may be adapted to create areliable grounding bond between frame 112 and coupling 138. As explainedbelow, mechanisms such as a grounding coupling may be used toelectrically connect the array 100 to a grounded component on supportstructure 103 or directly to the earth.

Prior to the module 102 being affixed to the mounted leveling foot 104 aas described above, a free-standing (not mounted to the support surface)leveling foot 104 b may be engaged with the groove 114 at the oppositeside of the module 102. The free-standing leveling foot 104 b may becoupled to the opposite side of the module by locking the key 150 of thefoot 104 b into the key slot 130 in groove 114. This is accomplished bysimply holding leveling foot 104 b at an angle of approximately 90° fromits final upright position, passing key 150 through the opening ofgroove 114, then rotating back 90° to engage the key with key slots 130a, 130 b. Key 150 may be shaped to allow it to pass through the openingof groove 114 when held at 90° from its final upright position, yetengage behind the lips of groove 114 when rotated to its final uprightposition. This manner of coupling is similar to the coupling of aninterlock 106 to modules 102, as explained in greater detail below,since both interlock coupling 164 and foot coupling 138 comprise a key150, 178 (see discussion below).

After a module 102 is coupled to a tongue 148 of a mounted leveling foot104 a, and the y-position of the module is adjusted for tolerances, theleveling foot 104 b coupled to the opposite side of the module 102 maythen be fastened to the support structure 103. Once the module isrotated down to its final orientation, the leveling foot 104 b now restson the support structure 103. The base 134 of leveling foot 104 b maysimply be rotated about the z-axis until it aligns with the joist orrafter beneath the support structure 103, and then bolted down toprovide a quick, easy and accurate attachment of the leveling foot 104b. The tongue 148 of leveling foot 104 b is oriented along the y-axisand ready to accept the next panel in the y-direction. Theabove-described process may then be repeated.

One skilled in the art will recognize that the arrangement of mounting aPV module 102 by means of a tongue connection on one side and a keyconnection on an opposite side, as shown in FIGS. 11-14, effectivelyutilizes the rigidity of support surface 103 to help create a rigidlyinterlocked array 100. If, for example, the leveling feet 104 of array100 were not attached to support surface 103, then the tongues couldeasily slide back out of grooves 114 if picked up to approximately the15° insertion angle as discussed above. This technique significantlyreduces the total materials required for an installation when comparedto conventional rail-based systems (which add rails for rigidity) orother interlocking systems which incorporate rigid coupling systems.Furthermore, the pivot-fit action as described in this disclosureprovides a rapid “drop-in” method for PV modules which is much fasterthan prior art systems that rely on press-fit connections and/orconventional fasteners.

In the embodiments described above, the key 150 of a free-standingleveling foot (104 b) is engaged with groove 114, and the tongue 148 ofa mounted leveling foot (104 a) is engaged with groove 114. It iscontemplated in further embodiments that this arrangement be reversed.That is, a key 150 of a mounted leveling foot may be engaged with groove114 and a tongue 148 of a free-standing leveling foot may be engagedwith groove 114. Moreover, in either embodiment, the key 150 may becoupled within the groove 114 before the tongue 148 on the oppositeside, or visa-versa. In still other embodiments, PV modules 102 of afirst row of array 100 may each be mounted by engaging the key 150 withgroove 114 on both the lower side and upper side in the orientationshown in FIG. 14, then subsequently attaching each of these upper andlower side leveling feet 104 to support surface 103. Subsequent rows maythen include the above method of including a tongue engagement on thelower side and a key engagement on the upper side.

In some embodiments, the couplings between connecting components such astongue 148 and the bearing portions 124, 128 are made without apress-fit and not by friction forces to hold the respective componentstogether. The rigidity of the final array in many embodiments isultimately derived from the roof or support structure, not the coupling.

FIG. 14 shows a first row of PV modules 102 assembled together onsupport structure 103. As seen in FIG. 14, in addition to leveling feet104, the present technology may employ interlocks 106 for affixingadjacent modules 102 together along the x-axis. The structure ofinterlock 106 will now be described in respect of the various views ofFIGS. 15 through 20. Interlock 106 in general includes an interlockplate 162 including a pair of openings 166 receiving a pair of interlockcouplings 164, which may be held in openings 166 via an interferencefit. As seen for example in a perspective view of FIG. 15, interlock 106includes a first surface 168 having a pair of ribs 170 spanning asubstantial portion of the length of interlock 106. In some embodimentsRibs 170 may also be shown on tongue side of plate thereby increasingthe structural properties of interlock 106.

An upper surface of the top rib 170 and a lower surface of the bottomrib 170 are spaced from each other so that the ribs together fitproperly within groove 114 as explained below. Instead of multipleseparate ribs, element 170 may instead comprise a single rib, or lug,having a top surface matching the top surface of upper rib 170 and abottom surface matching the bottom surface of lower rib 170. A lowerportion of interlock plate 162 may include a lip 172 which is positionedbeneath a lower surface of frames 112 of a pair of adjacent modules 102once interlock 106 is affixed to PV modules 102. Lip 172 may enhance thestructural performance of interlock 106 and may be omitted in furtherembodiments.

Each interlock coupling 164 may be identical to each other, and mayinclude a nut portion or flange, such as flange 174, a tongue 176extending in a first direction from the flange 174, and a key 178affixed to a shaft 180 extending in the opposite direction from flange174. Tongue 176 may be shaped like other tongues described in thisdisclosure such as the tongue of FIG. 8. The structure and operation ofkey 178 will now be described. It is understood that the key 150 onleveling foot 104 (referenced above with respect to leveling foot 104 b)may be structurally and operationally identical to key 178 on interlockcoupling 164, and the following description applies to the keys 178 and150 on both the interlock coupling 164 and foot coupling 138,respectively.

Key 178 rotates between a first, horizontal position to allow insertionof the key into groove 114 and a second, vertical position for lockingthe key within the key slot 130 of the medial portion 118 of groove 114.The reference to horizontal and vertical in the description apply whenthe interlock 106 is horizontal with respect to the x-y plane. If theinterlock were tilted, for example about the y-axis, the “horizontal”and “vertical” position of the key 178 would be adjusted accordingly.

The horizontal position of key 178 is shown by the interlock coupling164 on the right in FIG. 15, and in the cross-sectional side view ofFIG. 19. A key 178 in a vertical position is shown by the interlockcoupling 164 on the left side of FIG. 15, the interlock coupling of FIG.16 and the cross-sectional side view of FIG. 20. The interlock couplings164 of FIG. 15 are shown in different orientations for illustrationpurposes only, and it is understood that the left side interlockcoupling 164 would be in a horizontal position for insertion of theinterlock 106 into grooves 114 of adjacent modules 102 as explainedbelow.

In general, with the keys 178 of both interlock couplings in thehorizontal position, an interlock 106 is engaged with the grooves 114 ofmodules 102 adjacent to each other in the x-direction, with oneinterlock coupling 164 being inserted into each of the adjacent grooves114. The interlock 106 may be engaged with the ribs 170 at an angle thatmatches the insertion angle of upper and lower sloped surfaces 122 and126. A chamfer 182 may be provided at the bottom of lower rib 170 tomake it easier for ribs 170 to be inserted into the groove 114.

While completion of the pivot-fit connection of the groove 114 andtongue 148 of leveling foot 104 is facilitated by the moment forcegenerated by the weight of the module 102 at the coupling, no suchmoment force exists to facilitate coupling of the interlock 106 to frame112. Accordingly, the flange 174 and/or tongue 176 may be engaged by atool 183 (a portion of which is shown in FIGS. 19 and 20) which rotatesthe interlock coupling 164 from the horizontal to vertical position. Asthe key 178 rotates (about the y-axis), it engages within the key slot130 to pivot the ribs 170 (about the x-axis). The ribs pivot from theirinsertion position (parallel to the upper and lower sloped surfaces 122,124) to their final, coupled position (where the ribs 170 aresubstantially parallel to the planar surface of the module 102 and thex-y reference plane).

A lead-in bevel 184 is defined by a gradually increasing thickness ofthe key 178 from narrow to full width. This lead-in bevel allows theinterlock coupling 164 to gradually pivot about the x-axis from theangle of the groove 114 to zero degrees relative to the x-y referenceplane. This pivoting occurs as a result of the interlock coupling 164being rotated from its horizontal position to its vertical positionalong the axis of shaft 180.

A set of cutting teeth 188 are provided on the upper and lower portionsof the key 178 of each interlock coupling 164 in an interlock 106. Asthe key 178 is rotated from horizontal to vertical, the cutting teeth188 cut through the anodized layer in the groove 114 and make solidelectrical grounding contact with the aluminum or other metal of the PVmodule frame 112. Both of the interlock couplings 164 on an interlock106 may include these sets of cutting teeth 188. Thus, in addition tolocking adjacent modules 102 together, rotation of the interlockcouplings 164 also electrically couples the two electrical modulestogether. The grounding coupling explained below may connect the arrayto a ground state.

A chip gap 186 on each end of key 178 allows the teeth 188 to cut intosurfaces of the frame within the key slot 130 more effectively, andprovides a place for metal shavings from the cut to reside. A bump 187at the end of the key 178 also helps align the key by abutting againstback wall 132 of the distal region.

Flange 174 may include a detent 190 for being engaged by the tool 183 toallow quick and easy rotation of the interlock coupling 164 from itshorizontal to vertical position. The detent 190 may be located on anunderside of the interlock coupling 164 upon final rotation. Thislocation, as well as the custom shape of the detent 190, makes itdifficult to dismantle the interlock 106 from modules 102 without theproper tool to improve the security aspects of the system.

It is contemplated that some or all components of interlock 106 may bemanufactured from corrosion-resistant materials or may comprisecorrosion-resistant coatings to prevent galvanic and/or moisture-inducedcorrosion. Since foot coupling 138 may provide a ground bondingconnection between adjacent PV modules, such corrosion resistance mayhelp to prevent a loss of ground continuity over time.

FIGS. 21 through 23 show various side views of an interlock 106 beingaffixed to a pair of adjacent modules (one such module being visible inthe side view). FIG. 21 shows the ribs 170 of an interlock coupling 164being inserted between the upper and lower sloped surfaces 122, 126 offrame 112. The ribs 170 may be inserted at the insertion angle of theupper and lower sloped surfaces 122, 126 to provide maximum clearancefor the ribs 170 to enter into groove 114 (i.e., distance m, FIG. 4A).The width of the upper and lower ribs 170 together may be slightly lessthan or equal to the distance m. As indicated above, chamfer 182 on abottom surface of the lower rib may further aid in the initial insertionof the ribs 170 into groove 114. Upon initial insertion of the ribs 170into groove 114, the key 178 is in the horizontal position and as suchdoes not interfere with the insertion of the ribs between the upper andlower sloped surfaces 122, 126.

Once ribs 170 are manually inserted as far as they will go between theupper and lower sloped surfaces 122, 126, tool 183 may then be used torotate the interlock coupling from horizontal to vertical. FIG. 22 showsthe interlock coupling upon partial rotation of the key 178, the ends ofwhich are becoming more visible in the side view of FIG. 22. The lead-inbevel 184 pulls the key 178 into the key slot 130 behind the slopedsurfaces 122, 126. Thus, as the coupling 164 is rotated, the coupling ispulled into the groove 114 and pivots from the initial position shown inFIG. 21 to a final position where the key 178 is fully engaged withinkey slot 130. This final position is shown in FIG. 23.

As indicated above, when the interlock 106 is first inserted into groove114, the space in between the upper and lower sloped surfaces 122, 126as seen by the ribs 170 and shaft 180 may be the distance m describedabove in FIG. 4A. As the key 178 is pulled into the groove by rotationof the coupling 164, the ribs 170 and shaft 180 pivot from the insertionangle to a final position parallel to the x-y reference plane as shownin FIG. 23. In this position, the spacing between the surfaces 122, 126as seen by the ribs 170 and shaft 180 is the smaller distance n. In someembodiments, taking into account tolerance variations, the outerdiameter of the ribs (together) and shaft may be slightly larger than orequal to the distance n. For example, the diameter of the ribs and shaftalong this dimension may be 0.005″ smaller than the distance m, and0.005″ greater than the distance n. The size of the ribs 170 and/orshaft 180 relative to the distances m, n may vary from this in furtherembodiments.

Pivoting of the interlock coupling 164 from the position of FIG. 21 tothe position of FIG. 23 results in a pivot-fit connection between theinterlock 106 and groove 114. In particular, the ribs 170 and/or shaft180 bear against, and exert a force upward on, the bearing portion 124in the upper sloped surface 122 in the z-direction, and the ribs 170and/or shaft 180 bear against, and exert a force down on, the bearingportion 128 in the lower sloped surface 126 in the z-direction. Theseforces elastically deform the frame 112 around the groove 114 (in thedirection of arrows 151 in FIG. 23) so as to take up any variability inthe z-axis dimensions of the rails and/or shaft in the groove 114. Thisprovides a solid connection with respect to the z-axis and prevents anyrelative vertical movement between the interlock 106 and the corners ofthe adjacent modules in which the couplings of the interlock 106 areengaged. The key 178 bearing against the top and bottom slots 130 a, 130b of the key slot 130 may additionally or alternatively prevent relativemovement of the corners of the adjacent modules relative to theinterlock 106 and each other. Once key 178 enters groove 114, interlockplate 168 may begin to pivot primarily about bearing portion 124 asinterlock 106 rotates into its final position.

In one embodiment, in order to secure an interlock 106 to adjacentmodules 102, the interlock coupling 164 in the first module 102 may bepartially rotated to partially engage the key 178 of that coupling 164within the key slot 130 of the first module. The second coupling 164 ofthe interlock may then be fully rotated from horizontal to vertical tofully engage the second coupling within key slot 130 of the secondmodule 102. The rotation of the first coupling may then be completed tofinish the installation of the interlock 106. It is understood that theinstallation of an interlock may be performed by other methods, such asfor example fully inserting a first interlock coupling 164, and thenfully inserting the second interlock coupling 164 or by fully rotatingeach interlock coupling 164 immediately after insertion into groove 114.

As indicated above, the key 150 in leveling foot 104 may affix withinthe groove 114 in the same manner as described above with respect to key178 of the interlock 106. Thus, revisiting FIGS. 6 and 10, prior toseating a module 102 onto the tongue 148 of a leveling foot 104 a, theleveling foot 104 b may be affixed within the groove 114 at the oppositeside of the module 102 by inserting the key 150 into groove 114 androtating it by hand or with a tool as described above to engage the key150 into key slot 130.

FIG. 24 is a perspective view showing a pair of adjacent modules 102connected with an interlock 106 as described above. FIG. 24 furthershows a leveling foot 104 supporting the modules 102. FIG. 24 shows thetongue 148 of leveling foot 104 engaged within the groove 114, and nomodule engaging the key 150. In some embodiments tongues for interlockcouplings comprise catches as described elsewhere in this disclosure.The leveling foot 104 shown in FIG. 24 may for example be coupled at thevery front of the array 100 (e.g., one of the leveling feet 104 shown inFIG. 5). In alternative embodiments, leveling feet 104 at the front ofthe array may have a different configuration where key 150 is insertedinstead of tongue 148 or omitted. Modules 102 may be disassembled froman array 100 by performing the reverse operations to those set forthabove for mounting the modules 102 to the array 100.

In some embodiments, a PV module 102 may align with each adjacent module102 in the x-direction. However, the interlock 106 may operate evenwhere the modules 102 do not fully align in the x-direction. FIG. 24Ashows a plan view of four modules 102 a, 102 b, 102 c and 102 d. Themodules 102 a and 102 b are adjacent to each other in the x-direction,but do not completely align. Nevertheless, the interlock 106 may couplethe modules 102 a and 102 b together as described above. Interlock plate162 can slide in and out on interlock coupling shaft 180 therebyenabling ribs 170 to properly contact bearing portions 124, 128 ofgroove 114 even under misalignment conditions as shown. The shafts 180and ribs 170 of the interlock couplings 164 on interlock 106 are longenough so that the key 178 on one side of the interlock 106 may engagewithin the groove of the module 102 a, and the key 178 on the other sideof the interlock 106 may also engage within the groove of the module 102b, even though the interlock plate 162 is not parallel to the front edgeof either module 102 a or 102 b.

Any misalignment of modules 102 a and 102 b may be taken-up by theinterlock 106, and not transferred to the next row of modules 102 c and102 d. In particular, the modules 102 c and 102 d may seat over thetongues 176 of respective interlock couplings 164 on the back side ofthe interlock 106. As noted above, in the coupled position, the tonguestill allows for movement of a module with respect to the tongue in adirection parallel to the reference plane. Thus, the modules 102 c and102 d may be aligned with each other on the tongues 176, and anymisalignment of modules 102 a and 102 b does not transfer to the nextrow.

As noted above, where the array 100 is provided on a roof of aresidential dwelling, the position of the leveling feet 104 along thex-dimension of a module 102 may be determined by the location of arafter or joist beneath the roof. This typically will not align neatlyover the seams between adjacent modules (since PV modules are nottypically the same length as the standard spacing between rafters).Thus, leveling feet 104 may be used to support the array on the raftersor joists, and interlocks 106 may be used to couple together modules atthe seams. However, in further embodiments, it may be desirable to slidesome rows of modules further to the east or west than others; such aswith a hip roof where array 100 fits better if it follows the angle ofthe hip. In some embodiments it may be desirable to orient some rows ofmodules 102 in landscape orientation and others in portrait orientation.In these cases, interlock 106 may reside at the seams and/or at anypoint along the side of PV module 102.

In still further embodiments, array 100 is provided on a supportstructure 103 that is specifically provided to support the array (suchas for example in a ground-mounted array). In such embodiments, aninstaller is free to choose the position of the supports in thestructure 103, and may choose to line those supports up with the seamsbetween modules in the array. For such embodiments, a combined levelingfoot and interlock may be used.

One embodiment of a combined leveling foot and interlock 191 is shown inFIG. 25. While such a component may have a variety of configurations, inone example, the component 191 may include a foot 192 including a pairof double threaded studs 140 as described above with respect to theleveling foot 104. A pair of foot couplings 138 may be affixed to thefoot 192, spaced apart from each other on the studs 140 so that they canengage in the corners of first and second pairs of modules. The firstcoupling 138 may be affixed to the corners of the first pair of adjacentmodules in the y-direction as described above. Likewise, the secondcoupling 138 in the span may be coupled to the corners of the secondpair of adjacent modules in the y-direction as described above. Thus, asingle component may be used to fix together the corners of fouradjacent modules, support those modules at a desired height above asupport surface, and electrically ground those modules together.

The present technology may include additional couplings that mountwithin groove 114 in further embodiments. In some embodiments, a commonelement for all these additional couplings may be a key as describedabove (for example with respect to key 178) that engages with the groove114 to make a mechanical and electrical connection to the PV moduleframe 112. In other embodiments a common element may be a tongue such asdescribed above (for example with respect to tongue 148) or any maleprotrusion capable of engaging with groove 114.

As noted above, one such coupling may be a grounding coupling 194 asshown in FIG. 26. The grounding coupling 194 is used to connect agrounding wire (not shown) to one or more PV module 102 of the array100. The grounding wire is passed through a lay-in-lug channel 195 andthen a terminal screw 196 may be turned until a secure ground is madewith the grounding wire. The grounding coupling 194 may further includeother features of the above-described couplings, such as threaded hole197 for receiving a double threaded stud that allows the groundingcoupling to be supported on the support structure 103 via a base 134described above with respect to the leveling foot 104. The groundingcoupling may further include a key 178 as described above for lockingwithin a key slot 130 in a groove 114 to couple the grounding coupling194 to a module 102 of the array 100.

It may happen that other accessories need to be affixed to modules 102of the array 100. FIG. 27 shows a further coupling, referred to as anaccessory coupling 198, for affixing such accessories to modules of thearray. The accessory coupling 198 has a key 178 as described above forlocking within a key slot 130 in a groove 114 to attach the accessorycoupling 198 to a module 102 of the array 100. The accessory couplingmay include a flange 174, a shaft 180 between the key 178 and flange174, and a detent 190. Each of these components may be structurally andoperationally the same as the like components described above forinterlock coupling 164.

The flange 174 may be used to actively hold any type of componentagainst the PV module frame 112 once the accessory coupling 198 isturned from its horizontal insertion position to its vertical lockedposition. Referring to FIG. 28, the accessory coupling 198 may forexample hold a component 199 for PV module inverters, or any other typeof electronic device that may be mounted and, possibly, grounded to thePV module frame 112. In the embodiment of FIG. 28, the component 199 maybe held under the PV module 102. The accessory coupling 198 could alsomount and ground wire junction boxes or wire management systems. Thepresent application covers any device that can be mounted to the PVmodule frame 112 with a coupling device as described above and/or below.

In the above-described embodiments, PV modules 102 include a frame 112having a novel groove design for engaging with the tongue and/or key andshaft of different couplings. However, those skilled in the art willrecognize that generally female parts can be switched for generally maleparts and vice versa, therefore further embodiments of the presenttechnology may operate with PV modules 102 not having a groove 114. Forexample, FIGS. 29 and 30 show a wraparound leveling foot 204 where acoupling or bracket of the leveling foot 204 wraps around the upper andlower surfaces of a pair of PV modules 202 (not having a groove 114)adjacent along the y-axis. It is further understood that wraparoundleveling foot 204 may be used with a module 102 having groove 114 infurther embodiments.

Wraparound leveling foot 204 may include a base 206, and a coupling 208attached to the base 206 by double threaded stud 210. The base 206 andstud 210 may be identical to embodiments of the base 134 and stud 140described above with respect to leveling foot 104. In other embodiments,stud 210 is eliminated and base 206 is an integral part of base 214.Foot coupling 208 may include a hole 209 for receiving stud 210, androtation of the stud 210, for example by a tool within a tool receivingrecess 212 in the stud 210, may raise and lower the coupling 208 withrespect to the foot.

Coupling 208 includes a base 214 having a channel 216 and a threadedhole 218. Base 214 includes a first side 220 on a first side of channel216 and a second side 222 on the opposite side of channel 216. Ahorizontal portion of the base 214 on the first side 220 may have auniform vertical thickness, t. A horizontal portion of the base 214 onthe second side 222 has a first thickness, v, that is less than thethickness t, and a second thickness, t, which is the same as thethickness t on the first side 220. A sloped surface 223 may be providedconnecting the section of side 222 with thickness v to the section ofside 222 with the thickness t. The sloped surface 223 peaks at a bearingportion 237, which bears against a module 202 once the module is pivoteddown to its final position.

The coupling 208 further includes a top cap 224 and a top cap screw 226.The top cap 224 may seat within the channel 216, and a top cap screw 226may fit down through the top cap, and into threaded hole 218 in the base214. As indicated above, a hole 209 is formed through the coupling 208(including through base 214 and top cap 224) for receiving doublethreaded stud 210. The hole 209 may be threaded through the base 214,but may be larger in the top cap 224 so that the stud 210 engages thebase but not the top cap. Thus, rotation of the stud 210 will raise andlower the base 214, and the top cap supported on the base, but will notindependently act on the top cap.

Top cap 224 further includes a second hole 228, countersunk to receivetop cap screw 226. Top cap 224 includes a cap section 230 and a shaftsection 232. The shaft section 232 fits snuggly within channel 216 andthe screw 226 fits through hole 228 in cap 230 and shaft 232 into thetapped hole 218 in the base 214 to mount the top cap to the base. Aretaining ring may optionally be provided on top cap screw 226 beneaththe shaft 232.

In order to secure a pair of modules 202 to the leveling foot 204 andeach other along the y-axis, a first module 202 a is inserted in the x-yreference plane between the top cap 224 and the base 214 at the firstside 220. The top cap 224 may be loosely affixed to the base 214 at thispoint, or affixed to the base after module 202 a is engaged with side220 of the base. Once the module 202 a is positioned on base 214, topcap screw 226 may be tightened to firmly secure module 202 a towraparound leveling foot 204 between the top cap 224 and the base 214 atthe first side 220. An underside of the cap section 230 of top cap 224may include ridges 236 to ensure a good grip of the top cap 224 againstthe module 202 a when the top cap is tightened down.

Base 214 may include one or more electrical grounding teeth 238, forexample in the shape of an inverted v, for cutting through the anodizedlayer of the module 202 a. When the top cap 224 is tightened downagainst module 202 a, the teeth 238 bite through the anodized layer toengage the aluminum or metal layer of the module 202 a to provideelectrical grounding for the module 202 a. In further embodiments, theridges formed in the underside of the capped section 230 mayalternatively or additionally cut into and through the anodized layer toengage the aluminum or other metal layer beneath the anodized layer toprovide electrical grounding of the module 202 a.

Once the first module 202 a is affixed and the top cap 224 is inposition, the second module 202 b may be inserted at an angle betweencapped section 230 and slope 223. The sloped surface 223 may be providedat an angle as in the insertion angle described above with respect togroove 114. The insertion angle of slope 223 allows the module 200 b tobe easily inserted at an angle matching the insertion angle, and thenpivoted down on pivot points into the x-y reference plane to engage themodule 202 b between the base 214 and the top cap 224 (which is fixed inplace around the first module 202 a).

The distance between the outer edge of cap section 230 and slope 223 isat least as great as the thickness of modules 202 in a directionperpendicular to the slope 223. Once inserted as far as it will go atthe insertion angle, the module 202 b is pivoted downward to reside inthe x-y reference plane of the array, thereby creating a pivot-fitconnection similar to that described above. One skilled in the art willrecognize that the pivot-fit connection of FIG. 30 still allows fortake-up of dimensional variations since module 202 b is notsignificantly constrained in the y-axis once it has been pivoted intoposition, yet it is substantially constrained in the z-axis by top cap224 and base 134. Portions of the second side 222, such as for exampleslope 223, may include one or more electrical ground teeth 238 asdescribed with respect to first side 220. Teeth 238 may still maintainreliable electrical contact even with small variations in module 202 bposition along the y-axis. Wraparound leveling foot 204 allows PVmodules having no groove to be coupled and electrically groundedtogether and supported on a support surface. Moreover having top cap 224which screws down onto the modules allows the wraparound leveling foot204 to be used with modules of different thicknesses. In furtherembodiments, the top cap screw 226 may be omitted and the top cap 224may be integrally formed with, or otherwise permanently affixed to, base214. Such an embodiment may be used with modules 202 having a singleuniform thickness.

FIG. 30A shows an alternative embodiment of a wraparound leveling foot600. Wraparound leveling foot 600 is similar to wraparound leveling foot204, but wraparound leveling foot 600 may be formed of a unitaryconstruction without any movable components. In particular, wraparoundleveling foot 600 may include a bracket 602 including a horizontal baseportion 602 a, and a vertical portion 602 b. Base portion 602 a mayinclude an opening 604 for mounting the leveling foot 600 to a supportstructure 103. In embodiments, the height of wraparound leveling foot600 is not adjustable, so that leveling foot 600 may be best suited toconnection to a straight surface such as a rail 256 described below, forexample with respect to FIG. 38. However, the leveling foot 600 may beconnected to the support structure 103 by other methods in furtherembodiments.

The vertical portion 602 b includes upper flanges 606 and 608 extendingfrom opposite sides of vertical portion 602 b, and lower flanges 610 and612 extending from opposite sides of vertical portion 602 b. The lowerflanges may be angled upward from their connection point with verticalportion 602 b at some angle, for example the above-described insertionangle.

As described above with respect to FIG. 29, a first PV module (not shownin FIG. 30A) may be inserted at an angle between upper flange 606 andlower flange 610. The angle may be the insertion angle of lower flange610, and may for example be 15°, though it may be other angles infurther embodiments. Once inserted so that the PV module abuts againstthe vertical portion 602 b, the PV module may be pivoted down into thex-y reference plane until the module bears against a bearing portion 616in the upper flange 606 and a bearing portion 618 in the lower flange610. At this point, the PV module may be secured to the wraparound footcoupling 600 and constrained against movement in the vertical direction.It may still be adjusted in the reference plane. A second PV module maybe affixed to the wrap around foot coupling 600 on the opposite side ofthe vertical portion 602 in the same manner. The wraparound module 600may further include grounding teeth, such as the grounding teeth 238described above with respect to FIG. 29.

FIGS. 31 and 32 are perspective and side views of a wraparound interlock240 according to embodiments of the present technology. Wraparoundinterlock 240 is structurally and operationally similar to wraparoundleveling foot 204, and components in FIGS. 29 through 32 having the samereference numbers have like functionality. One difference is that whilewraparound leveling foot 204 is provided to couple a single pair ofmodules adjacent to each other in the y direction, wraparound interlock240 is provided to couple two pair of modules adjacent each other in thex and y directions. Accordingly, the base 214 of wraparound interlock240 is similar to base 214 for wraparound leveling foot 204, but thebase 214 of interlock 240 is longer in order to span the corners of fourmodules adjacent in the x-direction and y-direction.

A second difference may be that the base 206 and stud 210 of thewraparound leveling foot 204 may be omitted from the interlock 240.Thus, the wraparound interlock 240 in some embodiments can coupletogether four corners of adjacent modules, but does not support thosemodules on the support structure 103. In further embodiments, thewraparound leveling foot 204 and wraparound interlock 240 may becombined so that the base 206 and stud 210 of the wraparound levelingfoot may be added to the structure of wraparound interlock 240. Theresulting coupling would couple together the corners of four adjacentmodules, and support those modules at an adjustable height on thesupport surface.

In accordance with the above, the wraparound interlock 240 shown inFIGS. 31 and 32 may include a pair of top caps 224 provided withinchannel 216. Alternatively, wraparound interlock 240 may include asingle top caps 224 which spans the entire length of the base 214. Insuch an embodiment, top cap 224 may have a single top cap screw 226 fortightening the top cap down onto the four corners of adjacent PVmodules, or a pair of top cap screws through a pair of top cap screwholes for tightening the top cap 224 down onto the four corners ofadjacent modules. Once a first pair of modules 202 a is inserted intothe first side 220 of base 214, the top cap or caps 224 may be tighteneddown. Thereafter, a pair of second modules may be inserted into thesecond side 222 of base 214 at the insertion angle, and pivoted down tothe final coupled position (shown in FIG. 32) to create a pivot-fitconnection similar to that described above. As above, the screw-down topcap may be omitted in favor of an integrally formed top cap for workingwith modules of a single, uniform thickness.

FIGS. 32A through 32C show a further embodiment of a wraparound coupling400. The coupling 400 of this embodiment may include a base plate 402and a screw 404. While a single screw 404 is shown in FIG. 32A, thewraparound coupling 400 may include a second screw for engaging a secondpair of modules as explained below. The screw 404 may have a head 406.The wraparound coupling 400 may further include grounding teeth 412 on afirst side of the base plate 402, and grounding teeth 410 on a secondside of the base plate 402.

FIG. 32B shows a side view of the wraparound coupling 400 connectingtogether a pair of modules 202 a and 202 b in the y-direction via thescrew 404. A second screw 404 (not seen in the side view of FIG. 32B)would similarly connect together a second pair of modules (not seen inthe side view of FIG. 32B) adjacent to modules 202 a and 202 b in thex-direction. In operation, the first module 202 a is brought against afirst side of the wraparound coupling 400 and the screw 404 is tighteneddown until the module 202 a is held by head 406. Thereafter, a secondmodule 202 b may be brought in, for example at the insertion angle shownin phantom in FIG. 32B, until contact with a stop 416 formed on the baseplate 402. The second module 202 b may then be pivoted downward asexplained above to couple the second module 202 b to the wraparoundcoupling 104. The grounding teeth 412 may engage metal within the firstmodule 202 a when the screw 404 is tightened down, and the groundingteeth 410 may engage metal within the second module 202 b when themodule 202 b is pivoted down to its final position.

FIG. 32C shows an embodiment of a wraparound coupling 420. Coupling 420is similar to coupling 400 shown in FIGS. 32A and 32B, but in FIG. 32C,the wraparound coupling 420 is adapted to be supported on a supportstructure as in support structure 103 described above. For this purpose,wraparound coupling 420 includes a base 422 for being supported on asupport structure as in support structure 103, and a stud 424, which maybe any of the studs described above for mounting a coupling on a base.The modules 202 a and 202 b may be affixed to wraparound coupling 420 asdescribed above with respect to wraparound coupling 400.

FIG. 32D shows an alternative embodiment of a wraparound interlock 620.Wraparound interlock 620 is similar to wraparound interlock 240 of FIG.31, but wraparound interlock 620 may be formed of a unitary constructionwithout any movable components. In particular, wraparound interlock 620may include a vertical portion 622, upper flanges 626 and 628 extendingfrom opposite sides of vertical portion 622, and lower flanges 630 and632 extending from opposite sides of vertical portion 622. The lowerflanges may be angled upward from their connection point with verticalportion 622 at some angle, for example the above-described insertionangle.

As described above with respect to FIG. 31, the wraparound interlock 620may be inserted over a first PV module (not shown in FIG. 32D) at anangle with upper flange 626 and lower flange 630 fitting over the upperand lower edges of the frame. The angle may be the insertion angle oflower flange 630, and may for example be 15°, though it may be otherangles in further embodiments. Once inserted so that the PV module abutsagainst the vertical portion 622, the interlock 620 may be pivoted downthe PV module bears against a bearing portion 636 in the upper flange626 and a bearing portion 638 in the lower flange 630. At this point,the wraparound interlock 620 may be secured to the PV module. A secondPV module may be affixed to the wraparound interlock 620 on the oppositeside of the vertical portion 622. The wraparound interlock 620 mayfurther include ground teeth, such as the ground teeth 238 describedabove with respect to FIG. 31.

FIG. 33 shows a perspective view of a PV array 200 assembled togetherusing wraparound leveling feet 204 and wraparound interlocks 240. Asseen, wraparound leveling feet 204 located between adjacent modules 202in the y-direction are used to couple those modules together and supportthe array 200 on a support structure 103. Wraparound interlocks 240located between adjacent modules in the x-direction and adjacent modulesin the y-direction may be used to couple together the corners of fouradjacent modules. While the embodiment of FIG. 33 shows foot bases 206on interlocks 240, other embodiments contemplate use of interlock 240 asshown in FIG. 31 instead. In an alternative embodiment, either the firstside 220 or the second side 222 may be omitted from wraparound interlock240 so that it connects only adjacent modules in the x-direction and notthe y-direction. Given the above disclosure, those of skill willappreciate that other couplings, such as an electrical ground couplingand an accessory coupling, may be configured as wraparound couplings infurther embodiments.

To this point, the PV modules have been described as a laminate 110within a frame 112. However, it may happen that a solar array iscomprised of PV laminates 110 without a frame 112. FIGS. 34 through 36show a further embodiment of a coupling for coupling together laminates110 having no frame. Laminates 110 are still sometimes referred to as PVmodules 110 since they comprises electrical connections. Framelessinterconnect 250 may be used to couple together a pair of framelesslaminates in the y-direction, a pair of laminates in the x-direction, orat the corners of four laminates adjacent in both the x-direction andy-direction.

Frameless interconnect 250 in general includes a coupling 252 affixed toa mounting screw 254. The mounting screw 254 is in turn affixed within arail 256 of a system of rails laid down on the support structure 103.Coupling 252 may include a first side having a first groove 258 formedinto the coupling along the side of the coupling and angled downwardfrom the exterior surface inward. The angle may for example be theinsertion angle of 15°, but may vary in further embodiments of theinvention. Coupling 252 may similarly include a second, opposed sidehaving a second groove 262 configured as the mirror image of the firstgroove 258, i.e., along the side of the coupling and angled downwardinto the coupling at for example an angle of, for example, 15°.

The grooves 258 and 262 receive a bare laminate, and the grooves mayinclude a pliant lining 264 of, for example, rubber, to preventfracturing of the laminate edges received within the grooves. In orderto mount a PV laminate within the first or second grooves 258, 262, thelaminate is inserted at an angle matching the insertion angle of thegroove, and thereafter pivoted downward to create a pivot-fitconnection. The coupling 250 includes bearing portions 259, which bearagainst a PV laminate 110 on first and second sides of the coupling oncethe laminate is pivoted down to its final position.

The coupling 252 may be affixed to support structure 103 via mountingscrew 254 and rails 256. The coupling 252 may be supported on mountingscrew 254 in a number of ways. In a first embodiment, coupling 252 mayhave threads engaging with threads of mounting screw 254 so thatrotation of the mounting screw 254 relative to the coupling 252 resultsin movement of the coupling up or down along the mounting screw. In asecond embodiment (shown in FIG. 34), once the screw 254 is mountedwithin the rail 256 as explained below, the space between a head 254 aof mounting screw 254 and the rails 256 may be approximately equal tothe height of the coupling 252. In such an embodiment, the position ofthe coupling 252 is then fixed when the screw 254 is mounted in thetrack. A further embodiment may be similar to that described above andshown in FIG. 34, but a spring-biased mechanism may be positioned on themounting screw. The spring-biased mechanism may have a first end biasedagainst a lower surface of coupling 252 and a second end biased againstan upper surface of rail 256. Thus, the coupling 252 is pressed upwardagainst the head 254 a and the portions of the mounting screw fittingwithin the rail (explained below) are biased against an interior, uppersurface of the rail.

In some embodiments, the frameless interconnect 250 mounts within rails256, which may be affixed to the support surface along the x-axis and/ory-axis. The rails 256 may be positioned at locations which correspond tothe seams between adjacent PV laminates 110, but need not correspond toboth axes in some embodiments. As seen in FIG. 35, a rail 256 may have asubstantially C-shaped cross-section. The rail 256 may include opposedsurfaces 260 and 262 and wider than a key slot 264 accessible throughopposed surfaces 260 and 262.

In one embodiment, mounting screw 254 may include a key 268 at its basehaving a length greater than its width. When the width dimension of key268 (visible in FIG. 34) is aligned between opposing surfaces 260 and262, the width dimension may fit between the opposed surfaces 260, 262to allow insertion of the mounting screw into the key slot 264.Thereafter, the mounting screw may be rotated 90° so that the lengthdimension of key 268 locks within key slot 264. The length dimension ofkey slot 264 is visible in the cross-sectional view of FIG. 35. Thoseskilled in the art will appreciate a variety of other mechanisms forsupporting the coupling 252 on a support surface. In a furtherembodiment, a foot and double threaded stud, as for example describedabove with respect to leveling foot 104, may be provided and coupling252 mounted on the stud. In such an embodiment, rails 256 may beomitted.

FIG. 36 shows a plan view of an array which can be formed using theframeless interconnect 250. It shows a number of framelessinterconnects, each connecting together four adjacent PV laminates 110at their corners. FIG. 36 further shows rails 256 oriented in they-direction. The rails 256 may be oriented in the x-direction in furtherembodiments. In further embodiments, the frameless interconnect 250 maybe halved along the y-axis so as to join only two adjacent modules alongthe y-axis, or the frameless interconnect 250 may be halved along thex-axis so as to join only two adjacent modules along the x-axis.

The PV array described above for example with respect to FIG. 1 may liein a flat x-y reference plane on an inclined support structure 103, suchas for example the roof of a residential dwelling. It is understood thata PV array may also be provided on a flat surface, such as for example acommercial roof or a ground-mounted array. FIGS. 37 through 39illustrate a tilt interlock 280 which may be used for example to mountPV modules on a flat surface, where each module is provided at aninclined angle with respect to the support surface and x-y referenceplane in order to optimize the angle of incidence of solar radiation. Itis understood that the PV array in the x-y reference plane of FIG. 1 maybe mounted on a flat surface, and it is understood that the PV arraydescribed with respect to FIGS. 37 through 39 may be mounted on aninclined surface.

The tilt interlock 280 may be configured to operate with modules havingan angled groove 114 (as shown in FIGS. 37 and 38) or modules not havingan angled groove (as shown in FIG. 39). Referring initially to FIGS. 37and 38, there is shown an interlock 280 including a first upright 282spaced from, and generally parallel to, a second upright 284. The firstand second uprights may be integrally formed with, or otherwiseconnected to, a base plate 286. First upright 282 extends a greaterdistance away from the base plate 286 in the z-direction than the secondupright 284. The tilt interlock 280 may be formed for example ofextruded or rolled aluminum or some other metal such as rolled steel.

The first upright 282 may include a pair of holes 288 for receiving afirst set of couplings 290. The second upright 284 may include a pair ofholes 292 for receiving a second set of couplings 294. And the baseplate 286 may include a mounting hole 296 for receiving a base platecoupling 298. Base plate 286 may further include a pair of alignmenttongues 300 stamped from the base plate and extending downward to alignthe tilt interlock with a rail as explained hereinafter. The length ofthe base plate between the first and second uprights may be selected toprevent the first upright 282 from casting a shadow on the PV modulemounted to the second upright 284.

A first pair of PV modules adjacent to each other in the x-direction(one of which visible in FIG. 38) may be affixed to the first upright282 via a first set of couplings 290. The opposite end of the first pairof PV modules (not shown) is supported on a second upright 284 of thenext tilt interlock 280. Thus, the PV modules are mounted at an anglewhich is a function of the difference in height of the first and seconduprights 282, 284 and the length of the PV modules. In some embodiments,this angle may vary between 1° and 30° and may for example be 10° (notethat this angle is independent of the insertion angle discussed aboveand hereinafter with respect to a pivot-fit connection which may berelated to a final plane of a PV array or a row of PV modules). In someembodiments, the first pair of PV modules may form a right angle on thefirst upright 282 when coupled thereto. As the PV modules are angled asdiscussed above, the first upright 282 may also be angled with respectto vertical at the same angle that the PV modules form with horizontal.

As indicated, upright 282 includes a first set of couplings 290, whichin some embodiments, may each comprise an accessory coupling asdescribed above with respect to FIG. 27. As described above, suchcouplings may be mounted through holes 288 with a key engaging a groove114 of the first pair of modules, and a flange braced against a surfaceof upright 282. In some embodiments upright 282 further comprises ribs170 as described above.

A second pair of PV modules adjacent to each other in the x-direction(one of which visible in FIG. 38) may be affixed to the second upright284 via a second set of couplings 294. The opposite end of the secondpair of PV modules (not shown) is supported on a first upright 282 ofthe next tilt interlock 280, thus mounting the second pair of PV modulesat the same angle as the first pair of PV modules. The second upright284 may also be tilted at the same tilt angle, e.g. 10°, so that thefinished coupling between the second upright 284 and second pair ofmodules is at a right angle.

The second upright 284 may include a pair of couplings 294 having atongue such as for example tongue 148 described above with respect toleveling foot 104. In order to mount the second pair of PV modules 102 bon the respective tongues of the second set of couplings 294, themodules are inserted over the tongues at an angle equal to the tiltangle plus the insertion angle. Where the tilt angle is 10° and theinsertion angle is 15°, the PV modules 102 b may be inserted at an angleof 25° with respect to horizontal. Again, these angles are by way ofexample only. At such an angle, the upper and lower sloped surfaces 122,126 in the groove 114 of PV modules 102 b are parallel to and alignedwith the tongues 148 of the respective couplings 294. Once engaged overthe tongues of the second couplings 294, the PV modules 102 b may bepivoted downward to the final tilt angle to provide the above-describedpivot-fit connection of the second pair of modules 102 b with the tiltcoupling 280. The tongues on couplings 294 may comprise grounding teethas described for tongues 148; other embodiments contemplate no groundingteeth on the tongues of couplings 294.

The tilt interlock 280 may be mounted to a variety of support surfacesby a variety of fastening mechanisms. In the embodiment shown, the tiltinterlock 280 is mounted to a support structure 103 via rails 256 suchas described above with respect to FIG. 35. In such an embodiment, thebase plate coupling 298 may include a key 302 which may be fit within akey slot and then rotated to engage the key within the rail 256. A pairof alignment tongues 300 may also fit down within the channel definedbetween opposed surfaces 260, 262 in the rail 256 to align and maintainthe tilt interlock 280 in the proper orientation with respect to rail256.

The rails 256 in any of the above described embodiments may be mounteddirectly to the support surface, which may for example be a flat roof ora ground-mounted support system. Alternatively, the rails may besupported on support blocks so as to be spaced from the support surface.Those skilled in the art will appreciate a wide variety of other methodsfor mounting tilt interlock 280 to a support surface. In one furtherembodiment, tilt interlock 280 may include a foot and double threadedstud such as for example those described above with respect to levelingfoot 104. In such an embodiment, base plate 286 may include a threadedhole for receiving the double threaded stud. In this instance, the baseplate coupling 298 and rails 256 may be omitted. In other embodiments,tilt interlock 280 is held down via ballast material and/or pans withballast material in them.

FIG. 39 shows a wraparound tilt interlock 310, which may be structurallyand operationally similar to tilt interlock 280, except that it isdesigned for pivot-fit connections at both ends of each PV module 102.Interlock 310 may be configured to operate with PV module frames notincluding a groove 114 or with frameless laminates. Instead of the firstand second set of couplings 290, 294, the wraparound tilt interlock 310may include a first set of gripping arms 312 in the first upright 282and a second set of gripping arms 314 in the second upright 284. Atleast the bottom arm of the first and second set of gripping arms 312,314 may be angled upward by the insertion angle as described above,which may for example be 15°. The insertion angle here is with respectto the first and second uprights 282, 284, which as explained above areprovided at a tilt angle with respect to vertical such as for example10°.

In order to install a first pair of PV modules positioned side by sidewith each other along the x-direction (one such module visible from theside view of FIG. 39) on upright 282, the modules are brought in at anapproach angle matching the insertion angle minus the tilt angle of thefirst set of gripping arms 312. Where for example insertion angle is 15°and the tilt angle is 10°, this net angle will be 5° from horizontal. Itis understood these angles are provided by way of example only and mayvary in further embodiments. Once the PV module(s) are inserted betweenthe first set of gripping arms 312, they may be pivoted downward totheir final orientation at the tilt angle to provide the pivot-fitconnection. The first set of gripping arms 312 may include bearingportions 316, 319 which bear against the PV module(s) when rotated totheir final position to secure the PV modules between the gripping arms312. In some embodiments, these bearing portions may include cuttingteeth to provide an electrical ground connection between the modules inthe first pair of modules. In some embodiments interlock 310 is pivotedinto position onto module 102 when making the upper connection, whereasthe module 102 is dropped into the lower connection and pivoted down,thereby enabling a rapid succession of such operations in thenorth-south direction.

In order to install a second pair of PV modules positioned side by sidewith each other along the x-direction (one such module visible from theside view of FIG. 39) on upright 284, the modules are brought in at anapproach angle matching the insertion angle plus the tilt angle of thesecond set of gripping arms 314. Where for example insertion angle is15° and the tilt angle is 10°, this net angle will be 25° fromhorizontal. It is understood these angles are provided by way of exampleonly and may vary in further embodiments. Once the PV module(s) areinserted between the second set of gripping arms 314, they may berotated downward to their final orientation at the tilt angle. Thesecond set of gripping arms 314 may include bearing portions 318, 319which bear against the PV module(s) when rotated to their final positionto secure the PV modules between the gripping arms 314. In someembodiments, these bearing portions may include cutting teeth to providean electrical ground connection between the modules in the first pair ofmodules.

FIG. 40 shows a plan view of an array of PV modules assembled togetherusing either the tilt interlock 280 or the wraparound tilt interlock310. In some embodiments using a grooved frame and tilt interlocks 280,a first row of the tilt interlocks may be mounted to rails 256, with thetongues of the interlocks pointing inward toward the array. Thereafter,a pair of PV modules 102 may be dropped onto the tongues of a second setof couplings 294 in the first row of tilt interlocks 280. The PV modules102 may be pivoted downward to their final tilt position. At that point,a second row of tilt interlocks 280 may then have the keys of the firstset of couplings 290 inserted into the adjacent grooves in the PV moduleframe. The second row of tilt interlocks may then be fastened to therails 256. The process may then be repeated for the remaining PV modulesin the y-direction.

As seen in FIG. 40 and described above, the tilt interlock 280 may beused to join the corners of four PV modules adjacent along the x-axisand y-axis. In further embodiments, the tilt interlock 280 may be halvedalong the y-axis so as to join only two adjacent modules along they-axis, or the tilt interlock 280 may be halved along the x-axis so asto join only two adjacent modules along the x-axis.

In some embodiments described above, certain couplings have beendescribed as coupling along either the y-axis or the x-axis. However, itis understood that in further embodiments, any of the couplings may beused to couple along the y-axis and/or the x-axis. Embodiments of thesecouplings include a tongue, key or bracket used in any of a levelingfoot 104, interlock 106, wraparound leveling foot 204, wraparoundinterlock 240, frameless interconnect 250, tilt interlock 280 and wraparound tilt interlock 310. FIG. 41 shows one such example. In theembodiments described above, a tongue has been used for connectionsalong the y-axis. In the embodiment of FIG. 41, first and second tiltcouplings 326 and 328 each include a tongue 320 for connecting a PVmodule in the x-direction.

In the embodiment of FIG. 41, the PV modules 102 are inclined at anangle in their final positions, as described above with respect to FIGS.37 through 40. Thus, the first and second tilt couplings 326 and 329 maybe oriented along the y-direction, and the first tilt 326 coupling mayextend a shorter distance away from the support surface than the secondtilt coupling 328. The tilt couplings may be affixed to the supportsurface by any of the attachment systems described above.

In order to mount a next module 102 onto the tongues 320 of the firstand second tilt couplings 326 and 328, the module may be brought to thetilt couplings tilted about both the x-axis and y-axis. That is, asexplained above, in order to seat over tongues 320, a PV module isangled at the insertion angle, which may for example be 15°. As thetongues 320 with which the PV module are to couple lie along the y-axis,the module 102 may be angled at 15° about the y-axis so that the slopedsurfaces 122, 126 of the groove 114 of module 102 align over the tongues320 in the first and second tilt couplings.

If the modules 102 lay flat (i.e., in the x-y reference plane), thiswould be the only angle applied to PV module 102 to couple it to thetongues 320 of the couplings 326, 328. However, in this embodiment,there is also a tilt angle applied to the modules (the first tiltcoupling 326 is shorter than the second tilt coupling 328). Thus, themodule must also be tilted at the tilt angle to mate with the tongues320. The tilt angle is about the x-axis and may for example be 10°.Thus, with these angles in this example, the module may be angled 15°about the y-axis and 10° about the x-axis in order to properly orientthe module for mating over the tongues 320. After mating on the tongues320, the module 102 may then be tilted down around the y-axis to a zerodegree angle with respect to the y-axis to provide the module in thefinal, coupled position, tilted about the x-axis at the tilt angle.

In some embodiments described above, opposite facing portions of acoupling include either a tongue or a key, but not both. In furtherembodiments of the present technology, a single coupling may include apair of keys or a pair of tongues. Such an embodiment is shown forexample in FIG. 42. In the embodiment of FIG. 42, a double-key coupling322 is shown having a flange 324. A first key 327 and shaft 329 extendfrom a first side of flange 324, and a second key 330 and shaft 332extend from a second side of flange 324. Each of keys 327 and 330 may beas described above, for example with respect to key 178.

FIG. 43 shows one example for installing an array 100 using thedouble-key coupling 322, which is shown here further comprising anextension 336 to flange 324. Once a pair of modules 102 are providedadjacent each other, either in the x-direction or the y-direction, thedouble-key coupling 322 may be slid in between the modules so that thekeys 327, 330 seat within the grooves 114 of respective adjacent modules102. The keys may be slid in between the modules 102 and into thegrooves 114 of the respective modules while in the horizontal insertionposition. Thereafter, extension 336 may be used to help rotate thecoupling 322 such that the keys 327, 330 rotate to the vertical positionand engage in their respective grooves 114, coupling the modules 102together.

In a further embodiment, instead of sliding the double-key coupling 322into adjacent modules 102, the coupling 322 may be positioned with afirst key 327 within the groove 114 of a first module 102. Thereafter, asecond module may be moved into position to insert the second key 330into the groove 114 of the second module. Extension 336 may then be usedto engage the keys in the vertical position as described above. Acoupling having a pair of oppositely facing tongues may also beprovided.

FIGS. 44-48 show a further support coupling in the form of a front tiltfoot 440 (FIGS. 44 and 45) and a rear tilt foot 450 (FIG. 46). The fronttilt foot 440 and rear tilt foot 450 may be identical to each other withthe exception that a bracket 442 used in both feet 440, 450 may have anupwardly extending portion 442 a that is longer in the rear tilt foot450 than in the front tilt foot 440. The bracket 442 may for example beformed of ⅛ inch sheet steel, bent to form the upwardly extendingportion 442 a and a horizontal portion 442 b. The bracket 442 may beformed of different materials and to different thicknesses in furtherembodiments.

The upwardly extending portion 442 a on both feet 440 and 450 mayinclude an opening for receiving a coupling 444 having a tongue 446 anda key 448 extending from opposite sides of a flange 452. The tongue 446may be of the same type and construction as tongue 148 described above,and key 448 may be of the same type and construction as key 150described above. The flange 452 as shown has a hexagonal shape thatmatches the shape of the opening in the upwardly extending portion 442 aof feet 440, 450. The flange 452 may for example be swaged into theopening to provide a tight and permanent fit of the coupling 444 to thebracket 442. The flange 452 and opening may have other, correspondingshapes in further embodiments.

As shown in FIGS. 47 and 48, the front and rear tilt feet 440, 450 maybe adapted to be connected to PV modules 102 together side-by-side alongthe x-axis. As also seen in those figures, the PV modules may be tiltedrelative to the support structure 103, for example at 10°, as explainedabove for example with reference to FIGS. 37-40. As the couplings enterbetween modules along the x-axis, and as the modules are tilted aboutthe x-axis, the couplings 444 may similarly be tilted about an axialcenter of the coupling 444. This feature is shown for example in FIG.45, which shows the coupling tilted for use in the embodiment of FIG. 47an angle of 10°. The tilt angle of the coupling 444 may be provided tomatch the tilt angle of the PV module 102.

The tilt in the PV module 102 may be provided by the different lengthsof the upwardly extending portions 442 a of the front and rear feet 440,450, as seen for example in FIGS. 47 and 48. In order to insert the feet440, 450, they may be oriented generally parallel to the groove 114 inthe frame 112 so that the key 448 is oriented in the insertion positionas described above, for example with respect to FIG. 21. This initialinsertion position is shown in dashed lines for feet 440 and 450 in FIG.47. Thereafter, the feet may be rotated 90° to engage the key 448 withinthe groove 114 as described above, for example with respect to FIGS. 22and 23. Once a pair of front and rear feet 440, 450 are locked onto afirst PV module, another PV module adjacent in the x-direction may bedropped onto the tongues 446 of the front and rear feet as describedabove, for example with respect to FIG. 41.

In order to remove a foot 440 or 450, the foot may be rotated 90° backto the initial insertion position shown in dashed lines in FIG. 47, andpulled outward from the groove 114. Where modules are mounted adjacentto each other along the x-direction as shown in FIG. 48, it may not bepossible to pull a foot straight outward from the groove 114. In suchinstances, in order to remove a foot 440, 450, the foot may be rotatedback toward the initial insertion position. The horizontal portion 442 bmay contact the next adjacent module as the foot is rotated back towardthe initial insertion position so that the foot is not able to rotateback 90° to the initial insertion position. However, the foot may berotated sufficiently to free the key 448 from the groove, and allow thefoot 440 and/or 450 to then be slid out of the end of the groove 114(along y-axis).

In the embodiments including PV modules lying flat and parallel to eachother (such as for example shown in FIG. 1), a single reference planemay be defined for the entire array 100. However, where the array 100includes a tilted array (such as for example shown in FIG. 48), each PVmodule 102, or row of PV modules 102 along the x-axis, may have its ownreference plane. In tilted row embodiments, the reference plane may beparallel to the surface of the tilted PV arrays in a given row, and maybe located at or above an upper surfaces of the PV laminates 110 in thatrow, or at or below the lower surfaces of the PV laminates 110 in thatrow.

In the embodiments described above, the various support couplings weresupported on the support structure 103 either by fasteners into thesupport structure 103 or on rails, such as rails 256 in FIG. 38. In afurther embodiment, a leveling foot or other support coupling accordingto any of the above-described embodiments may alternatively include aballast tray and ballast. One example of this is shown in FIG. 48. Inthis embodiment, the horizontal portion 442 b of bracket 442 acts as aballast tray for supporting ballast 458. Ballast 458 may be any of avariety of relatively heavy objects, such as a paver, brick, concrete,sand bag, metal block, etc. In the embodiment shown, ballast 458 is ablock extending between and onto a pair of adjacent front and rear feet440, 450 (as shown for example by ballast 458 a in FIG. 48), though theballast may be supported on a single foot or across more than two feetin further embodiments. The horizontal portion 442 b may include anupwardly extending tab 454 for preventing the ballast 458 from slidingoff of the horizontal portion 442 b. The embodiments of FIGS. 47 and 48may alternatively be bolted to the support surface 103, either directlyor to rails such as rails 256 described above.

FIGS. 49 and 50 show side and perspective views of a mid-supportcoupling 460 which may be used to support a pair of tilted PV modulesalong the y-axis, and may engage the pair of adjacent PV modules withcouplings as described for example with respect to any of theembodiments of FIGS. 37-40. In the embodiment shown in FIGS. 49 and 50,the support coupling 460 may be situated along an x-axis side of a PVmodule 102, in between the ends of the module as shown, and an interlock106 may be used to join a pair of modules 102 together along the x-axis.

As described above with respect to FIGS. 37-40, the mid-support coupling460 may include a first upwardly extending support 466 for supporting anend of a first PV module at a first height above the support structure103, and a second upwardly extending support 468 for supporting an endof a second PV module at a second height above the support structure103. The differing heights of supports 466 and 468 provide the tilt ofthe PV modules 102 with respect to the support structure 103.

In the embodiment shown, a central portion 462 between the upwardlyextending supports 466 and 468 provides a ballast tray for supportingballast 464 as described above. The mid-support coupling 460 mayalternatively be mounted to the support surface 103 directly, or mountedto a rail, such as rail 256 of FIG. 38, extending in the y-direction.

FIGS. 51 and 52 show perspective and side views of a double-tongueleveling foot 470. The foot 470 includes a base 472 which, inembodiments, may be larger and/or bulkier than the foot 134 describedabove, for example with respect to FIG. 8. A double-tongue coupling 474may be affixed to the base 472 via a screw 484. In embodiments, screw484 may have threads only along a top portion of the screw (the portionof the screw engaged by coupling 474). The bottom portion of the screw484 may have no threads, but may be fixed to the base 472 via a pair ofpins 486. The pins may for example engage within notches (not shown) ina portion of the screw 484 within base 472 to allow rotation but nottranslation of the screw 484 relative to the base 472. Rotation of thescrew 484 while preventing rotation of the double-tongue coupling 474translates the coupling 474 along the screw 484 to a desired heightabove base 472.

The double-tongue coupling 474 may include a pair of tongues 476 and478. The tongues 476 and 478 are oppositely facing to each other forengaging within grooves 114 of PV modules 102 adjacent to each other inthe y-direction and/or x-direction. The tongues have a thickness alongthe z-direction as described above for engaging within a groove at theinsertion angle and thereafter rotated down to final engagement anglewithin a groove 114. The tongues 476 and 478 are shown with a widthwhich may be wider than for example tongue 148 described above, thoughthe width need not be greater in further embodiments. A pair of stops480 are shown on the coupling 474 to provide a hard stop as each tongue476, 478 is inserted into its respective groove 114. In general, thedouble-tongue coupling 474 may provide a higher strength than levelingfoot 104 and a simpler no-tool installation method.

FIG. 52A shows a perspective view of a double-tongue coupling 471 whichis similar to the double-tongue coupling 470 of FIGS. 51 and 52 with theexception that the double-tongue coupling 471 in FIG. 52A is integrallyformed with, or otherwise fixedly mounted to, a bracket 488. The bracket488 includes a base 488 a and an upwardly extending portion 488 b. Thedouble-tongue coupling 474 may be formed on top of the upwardlyextending portion 488 b. The coupling 474 in FIG. 52A may bestructurally and operationally as described above in FIGS. 51 and 52. Inembodiments, the height of double-tongue coupling 471 in FIG. 52A is notadjustable, so that double-tongue coupling 471 may be best suited toconnection to a straight surface such as a rail 256 described above.However, it is understood that double-tongue coupling 471 may befastened directly to a support structure such as a roof via a fasteneror ballast in further embodiments.

FIGS. 53 and 54 show perspective views of a stamped interlock 490. FIGS.53 and 54 are identical to each other with the exception that FIG. 54shows the interlock 490 with a pair of interlock couplings 164, wherethe couplings 164 are omitted from FIG. 53. Interlock couplings 164 maybe structurally and operationally identical to the interlock couplings164 described above, for example with respect to FIGS. 15-24. Thestamped interlock 490 may further include an interlock plate 491, formedfor example of a single piece of ⅛ inch sheet steel. Interlock plate 491may be formed of other material and to other thicknesses in furtherembodiments. The interlock plate 491 may be stamped to produce a numberof tabs 492 bent out of the plane of interlock plate 491. The tabs 492are operationally analogous to the ribs 170 described above with respectto FIGS. 15-23. In particular, the tabs 492 fit within a groove 114 atan insertion angle, and then may engage top and bottom bearing portions124, 128 of the groove 114 as the plate 491 pivots downward upon thekeys 178 being rotated from their insertion position to their lockedposition within the key slot 130 within groove 114.

Interlock plate 491 may be stamped in such a way so as to define leafsprings 494 and 496 as shown within a interior open portion of the plate491. These leaf springs 494, 496 may elastically deflect downward fromthe perspective of FIG. 53 to allow insertion and fastening of thecouplings 164 to the plate 491. The plate 491 may further include a lip172 as described above for example with respect to FIG. 15. In any ofthe above described embodiments of the interlock 106 and/or stampedinterlock 490, the lip 172 may be omitted. Alternatively, for any suchembodiments, a second lip (not shown) may be provided on a top portionof the interlock plate 162/491 so as to be positioned over a top edge ofthe frame 112 upon affixation of the interlock.

FIGS. 55 and 56 show perspective and side views of a hybrid, press-fitcoupling 500 including a support plate 502 and a press-fit leg 506. Thecoupling 500 may be used to mount PV modules in the reference planeparallel to the support structure, or may be used to mount PV modulestilted at an angle. Where tilted at an angle as in FIGS. 55 and 56, thebase 502 includes a low side 508 with a pair of couplings 294 such asdescribed above with respect to FIG. 37. One coupling 294 is visible inFIG. 53, while the other coupling 294 has its tongue 148 engaged withinthe groove 114 of PV module 102 and is hidden from view.

The base 502 further includes a high side defined by leg 506 which snapsonto base 502. In particular, the leg 506 includes a notch 516 capableof snapping over a protrusion 510 formed in a portion of the base 502 ina press-fit relationship. The leg 506 shown in FIGS. 55 and 56 may be aplastic component including structural ribs 514 for adding rigidity tothe leg 506. Leg 506 may be formed of other materials such as aluminumor steel in further embodiments, and ribs 514 may be omitted.

An upper portion of leg 506 includes a double ended coupling 518 forengaging a pair of PV modules 102 adjacent to each other in thex-direction in the embodiment shown. The double ended coupling 518 mayinclude a pair of keys extending in opposite directions for engagingwithin respective grooves 114 of the adjacent modules 102. Such acoupling is shown above as double-key coupling 422 in FIG. 42.Alternatively, the coupling 518 may have a pair of tongues for engagingwithin respective grooves 114 of the adjacent modules 102. Such acoupling is shown above as double-tongue coupling 470 in FIGS. 51 and52. The coupling 518 may further include one key and one tongueextending in opposite directions from each other off of the coupling 518to engage within respective grooves 114 of adjacent PV modules.

The leg 506 also includes a handle 512 for easy insertion of thecoupling 518 and removal of the coupling 518. In order to insert the leg506, the double-ended coupling 518 is inserted in between adjacentmodules 102 and rotated 90° downward until the notch 516 press-fits overthe protrusion 510 and the opposite ends of the double ended coupling518 engage within the respective grooves 102 of adjacent PV modules.

The base 502 may be supported on the support structure 103 by fastenersthrough the base and into the support structure 103, by being mounted torails such as rails 256, or by serving as a ballast tray and havingballast provided thereon.

FIGS. 57 and 58 show front and rear perspective views of a modularcoupling 520. The modular coupling 520 may include a plate 522 formedfor example of ⅛ inch sheet steel, though it may be other materials andthicknesses in further embodiments. The plate 522 may be bent into rightangle sections 522 a and 522 b. Section 522 a may formed to include acentral opening for receiving an accessory coupling 174, for example asdescribed above with respect to FIGS. 27 and 28. The section 522 a isfurther formed with two pair of opposed tabs 526 bent out of the planeof section 522 a. The tabs 526 serve dual functions as explained below.The section 522 b may be bent at a right angle with respect to section522 a, and may include a hole 528 allowing components to be bolted tothe modular coupling 520 as explained below.

FIG. 59 is a perspective view of a PV module 102 having a pair ofmodular couplings 520 affixed thereto. In embodiments, the section 522 ahas a square shape with a length and width approximately equal to aheight of a frame 112. The modular coupling 520 may be affixed to theframe 112 in one of four orientations: a first where the section 522 bis oriented perpendicular to the reference plane of module 102 and tothe right of the modular coupling (coupling 520 a in FIG. 59); a secondwhere the section 522 b is oriented perpendicular to the reference planeof module 102 and to the left of the modular coupling; a third where thesection 522 b is oriented parallel to the reference plane of module 102and at the bottom of the modular coupling (coupling 520 b in FIG. 59);and a fourth where the section 522 b is oriented parallel to thereference plane of module 102 and at the top of the modular coupling.

In the first and second orientations, a first pair of opposed tabs 526are received within groove 114, and the second pair of opposed tabs 526are positioned over the upper and lower edges of frame 112. In the thirdand fourth orientations, the second pair of opposed tabs 526 arereceived within groove 114, and the first pair of opposed tabs 526 arepositioned over the upper and lower edges of frame 112.

As described above, the accessory coupling 174 includes a key 178. Inorder to affix the modular coupling 520 a in FIG. 59, the key 178 ispositioned for insertion within the groove 114 at the insertion anglewhile the section 522 b is perpendicular to the reference plane.Thereafter, the key 178 is rotated as explained above to engage themodular coupling 520 a with the frame 112. In order to affix the modularcoupling 520 b in FIG. 59, the key 178 is positioned for insertionwithin the groove 114 at the insertion angle while the section 522 b isparallel to the reference plane. Thereafter, the key 178 is rotated asexplained above to engage the modular coupling 520 b with the frame 112.

The tabs 526 are structurally and operationally similar to tabs 492described above with respect to FIGS. 53 and 54. In particular, the tabs526 which fit within the groove 114 are inserted at the insertion angle,and then they may engage top and bottom bearing portions 124, 128 of thegroove 114 as the modular coupling 520 pivots downward upon the key 178being rotated from its insertion position to its locked position withinthe key slot 130 within groove 114.

Once the modular coupling 170 is affixed to the frame 112, variouscomponents may be affixed to the section 522 b via a bolt in hole 528.For example, FIG. 59 shows a component 530 affixed to the modularcoupling 520 a via a bolt 532. Other connections may be made to themodular coupling in any orientation, such as for example for connectinga module 102 to various types of surfaces as well as connecting atilt-up leg or ground-mount rack.

FIGS. 60 and 61 show perspective and side views of a foot bracket 540which connects to a PV module 102 with a pivot action similar tointerlock 106 described above. The foot bracket 540 includes a base 542with a hole 546 for receiving a fastener (not shown) for affixing thefoot bracket 540 to a support structure 103. In embodiments, the heightof foot bracket 540 is not adjustable, so that foot bracket 540 may bebest suited to connection to a straight surface such as a rail 256described above. However, it is understood that foot bracket 540 may befastened directly to a support structure such as a roof via a fasteneror ballast in further embodiments.

The foot bracket 540 further includes an upright section 544 includingribs 170 and an interlock coupling 164 which are structurally andoperationally the same as described above with respect to FIGS. 15-23.The coupling 164 includes a key 178 (FIG. 61). The key is positionedparallel to the ribs 170, and the key and ribs are inserted into thegroove 114 at the insertion angle. Thereafter, the key 178 is rotated topivot the foot bracket 540 down to engage the ribs 170 and key 178within the groove 114, completing the fastening of foot bracket 540 tothe frame 112 of module 102.

In the embodiments described above, the coupling engaging within thegroove 114 often engaged the upper bearing portion 124 and the lowerbearing portion 128. The coupling may engage other surfaces within thegroove 114 in further embodiments. FIG. 62 is a side view of one suchembodiment showing a key slot-engaging coupling 550. The coupling 550may be formed of ⅛ inch sheet steel, though it may be formed of othermaterials and other thicknesses, and need not be formed of a sheet ofsuch material, in further embodiments. The coupling 550 includes a base552 supported on the support structure 103. The base 552 is shown foldedinto two layers in FIG. 62, though it may be a single layer or more thantwo layers of folded material in further embodiments. A first upwardlyextending portion 554 extends from base 552. The length of firstupwardly extending portion 554 determines the height of the connected PVmodules above the support structure 103.

The coupling 550 may for example be two inches wide (into the page ofFIG. 62), though it may be wider or narrower than that in furtherembodiments. At a top of first upwardly extending portion 554, thecoupling may split along its width dimension, with a first horizontalsection 556 extending in the direction of the first PV module 102 a, anda second horizontal section 558 extending in the direction of the firstPV module 102 b. Section 556 has a second upwardly extending portion560, and section 558 has a third upwardly extending portion 562. Inembodiments, the second and third portions 560 and 562 may be samelength, to provide a PV array parallel to the support structure 103. Infurther embodiments, one of the second and third portions 560 and 562may be longer than the other, to provide PV modules which are tilted, asshown for example in FIG. 48.

In order to assemble PV module 102 a onto the coupling 550, the PVmodule 102 a may be inserted over the second upwardly extending portion560 at an insertion angle as described above until a top of the secondupwardly extending portion 560 engages within the key slot 130 of theframe 112 of the PV module 102 a. Once the second upwardly extendingportion 560 is engaged within the key slot, the PV module 102 a may berotated downward until the lower bearing portion 128 of frame 112engages the first horizontal section 556 of the coupling 550. At thispoint, the PV module 102 a is secured on the coupling 550.

In order to assemble PV module 102 b onto the coupling 550, the PVmodule 102 b may be inserted over the third upwardly extending portion562 at an insertion angle as described above until a top of the thirdupwardly extending portion 562 engages within the key slot 130 of theframe 112 of the PV module 102 b. Once the third upwardly extendingportion 562 is engaged within the key slot, the PV module 102 b may berotated downward until the lower bearing portion 128 of frame 112engages the second horizontal section 558 of the coupling 550. At thispoint, the PV module 102 b is secured on the coupling 550, adjacent thefirst PV module 102 a. Other configurations are contemplated where acoupling engages bearing portions other than bearing portions 124 and/or128 in further embodiments.

The foregoing detailed description of the inventive system has beenpresented for purposes of illustration and description. It is notintended to be exhaustive or to limit the inventive system to theprecise form disclosed. Many modifications and variations are possiblein light of the above teaching. The described embodiments were chosen inorder to best explain the principles of the inventive system and itspractical application to thereby enable others skilled in the art tobest utilize the inventive system in various embodiments and withvarious modifications as are suited to the particular use contemplated.It is intended that the scope of the inventive system be defined by theclaims appended hereto.

What is claimed:
 1. A grooved frame photovoltaic module, comprising: (a)a photovoltaic laminate having a top planar surface; (b) a frameextending around the photovoltaic laminate, the frame having a topsurface; and (c) a side groove in the frame, the side groove comprising:(i) an inner portion having a top surface and a bottom surface, the topsurface and the bottom surface being parallel to the top planar surfaceof the photovoltaic laminate; and (ii) an outer portion having anaperture passing therethrough, wherein an outer entrance into theaperture is disposed above an inner entrance into the aperture.
 2. Thegrooved frame photovoltaic module of claim 1, wherein the distancebetween the outer entrance into the aperture and the top surface of theframe is less than a distance between the inner entrance into theaperture and the top surface of the frame.
 3. The grooved framephotovoltaic module of claim 1, wherein the outer entrance into theaperture is closer to the top surface of the frame than the innerentrance into the aperture is to the top surface of the frame.
 4. Thegrooved frame photovoltaic module of claim 1, wherein the side groovefurther comprises: (iii) a mid-portion disposed between the inner andouter portions, wherein the mid-portion has an upper recess disposedabove the top surface of the inner portion of the side groove and alower recess disposed below the bottom surface of the inner portion ofthe side groove.
 5. The grooved frame photovoltaic module of claim 4,wherein the upper and lower recesses are parallel to the top planarsurface of the photovoltaic laminate.
 6. The grooved frame photovoltaicmodule of claim 1, wherein the frame and the side groove extend aroundfour sides of the photovoltaic laminate.
 7. The grooved framephotovoltaic module of claim 1, wherein a top edge of the outer entranceinto the aperture is disposed above a top edge of the inner entranceinto the aperture.
 8. The grooved frame photovoltaic module of claim 1,wherein a bottom edge of the outer entrance into the aperture isdisposed below a bottom edge of the inner entrance into the aperture. 9.The grooved frame photovoltaic module of claim 1, wherein the top of theaperture includes a bearing surface and the bottom of the apertureincludes a bearing surface, and wherein the bearing surface on the topof the aperture is at an inner edge of the aperture, and the bearingsurface on the bottom of the aperture is at an outer edge of theaperture.
 10. The grooved frame photovoltaic module of claim 1, whereinthe aperture in the outer portion of the side groove defines an angledinsertion path for a component to be received therein.
 11. The groovedframe photovoltaic module of claim 10, wherein the angled insertion pathis disposed at an angle to the top planar surface of the photovoltaiclaminate.
 12. A grooved frame for a photovoltaic module, comprising: (a)a frame having a top surface; and (b) a side groove in the frame, theside groove comprising: (i) an inner portion having a top surface and abottom surface, the top surface and the bottom surface being parallel tothe top planar surface of the photovoltaic laminate; and (ii) an outerportion having an aperture passing therethrough, wherein an outerentrance into the aperture is disposed above an inner entrance into theaperture.
 13. The grooved frame for a photovoltaic module of claim 12,wherein the distance between the outer entrance into the aperture andthe top surface of the frame is less than a distance between the innerentrance into the aperture and the top surface of the frame.
 14. Thegrooved frame for a photovoltaic module of claim 12, wherein the outerentrance into the aperture is closer to the top surface of the framethan the inner entrance into the aperture is to the top surface of theframe.
 15. The grooved frame for a photovoltaic module of claim 12,wherein a top edge of the outer entrance into the aperture is disposedabove a top edge of the inner entrance into the aperture.
 16. Thegrooved frame photovoltaic module of claim 12, wherein a bottom edge ofthe outer entrance into the aperture is disposed below a bottom edge ofthe inner entrance into the aperture.
 17. A grooved frame photovoltaicmodule, comprising: (a) a photovoltaic laminate having a top planarsurface; (b) a frame extending around the photovoltaic laminate; and (c)a side groove in the frame, the side groove comprising: (i) an innerportion having a top surface and a bottom surface parallel to the topplanar surface of the photovoltaic laminate; (ii) a mid-portion disposedadjacent to the inner portion, the mid-portion having a top surface anda bottom surface parallel to the top planar surface of the photovoltaiclaminate, wherein the top surface of the mid-portion is higher than thetop surface of the inner portion and the bottom surface of themid-portion is lower than the bottom surface of the inner portion; and(iii) an outer portion having an aperture passing therethrough, theaperture defining an angled insertion path for a component insertedtherein.
 18. The grooved frame for a photovoltaic module of claim 17,wherein the distance between the outer entrance into the aperture andthe top surface of the frame is less than a distance between the innerentrance into the aperture and the top surface of the frame.
 19. Thegrooved frame for a photovoltaic module of claim 17, wherein a top edgeof the outer entrance into the aperture is disposed above a top edge ofthe inner entrance into the aperture.
 20. The grooved frame photovoltaicmodule of claim 17, wherein a bottom edge of the outer entrance into theaperture is disposed below a bottom edge of the inner entrance into theaperture.